Handbook Foundation Form Work Rebar Concrete

Hand Book on Foundation,
Formwork, Rebar &

Concrete
Building Structure
Competency Center
PREFACE
Construction industry in India is growing at faster pace
and the Buildings & Factories Operating Company (B&F
OC) is no exception in terms of number, size and volume
of projects. This growth throws challenges in terms of
delivery without compromising on Quality, Safety and
Sustainability. To meet this challenge, human resource is
the prime mover and it is essential to upgrade the skill and
knowledge level of engineers and front line supervisors to
the latest technology that our company adopts to sustain our leadership in the
market.
B&F OCs entire business is grouped into three disciplines namely Structure,
Finishes and MEP. Building Structure Competency Cell (BSCC) of B&F OC
is created to provide total solutions to structure discipline in the areas of
Foundation, Formwork, reinforcement, Concrete and Pre-stressing.
BSCC has come out with a reference hand book on the methods and processes
adopted in construction of structure. I have gone through the book and found
it very useful for site engineers especially in
Understanding the basics
Application in respective field
DOs & DONTs
Specifications & Standards
With this handbook they will be able to largely address the day to day issues
that they face and thereby become self-sufficient.
I am sure that the BSCC site engineers and Supervisors will make use of this
hand book to improve the operational efficiency which should translate into
improved quality at optimum cost.
I appreciate the entire BSCC teams who have put inefforts to make this book
a comprehensive tool.
(A.L.Sekar)
Vice President & Head RBBU.
INDEX
CONTENTS
Page No.
ALUMINIUM FORM WORK

Introduction............................................................................................6
Worksite Management............................................................................6
Assembly & Dismantling Process..............................................................9
Flowchart for Aluform...........................................................................32
SLIP FORM
Introduction..........................................................................................34
Type of Slipform....................................................................................36
Assembly procedures............................................................................36
Tapering Slipform.................................................................................38
Assembly of stair tower..........................................................................39
Dismantling procedure..........................................................................40
Summary of Labour Productivity Norms..................................................43
Slipform Planning.................................................................................44
TUNNEL FORM
Aluminium Formwork Refurbishment......................................................47
Plywood...............................................................................................71
Form Release agent..............................................................................73
Formwork lift........................................................................................74
Automatic Climbing System...................................................................75
Hand tools required..............................................................................76
Guidelines for Formwork Engineer ........................................................33
Guidelines for Foreman/Charge hand...................................................78
System Formwork Functions, applications& Safety...................................79
REINFORCEMENT WORKS
Category of Reinforcements...................................................................91
Reference Indian standards...................................................................91
Reference International Standards..........................................................91
2
Hook & Bend Allowance........................................................................92

Bar bending Schedule Format................................................................93
Minimum diameter required for Bending Former....................................98
Cross-sectional area & Mass of Rebar....................................................99
Checks...............................................................................................100
Testing of Rebar..................................................................................101
Nominal cover....................................................................................104
Tips on Cover.....................................................................................104
Tolerance of cover...............................................................................104
Material for cover...............................................................................105
Photographs (Rebar)...........................................................................106
Prefabricated cage photos...................................................................109
Rebar tying machine...........................................................................109
Splicing methods................................................................................110
Precautions.........................................................................................110
Splicing strengths................................................................................110
Reinforcement couplers.......................................................................110
Coupler photographs..........................................................................111
Classification of test for Reinforcement couplers....................................112
Reinforcement Binding........................................................................113
Welding of Reinforcements..................................................................115
Precautions in Rebar activity.................................................................117
PILNG WORKS
Pile....................................................................................................119
Classification......................................................................................120
Factor governing Pile selection.............................................................112
List of Reference Codes.......................................................................125
Installation sequence
Driven cast in-situ piles...................................................................126
Bore cast in-situ piles......................................................................127
Characteristics of Bentonite suspension for BCIS piles...........................128
Important things to be followed...........................................................130
3
Driven cast in-situ piles...................................................................130

Bore cast in-situ piles......................................................................131
Driven precast...............................................................................132
Load test on Piles................................................................................134
Types of Arrangements........................................................................134
Vertical load test Arrangements.......................................................135
Lateral load test Arrangements.......................................................137
Pullout test arrangements...............................................................138
Pile Integrity test..................................................................................140
PDA Test.............................................................................................140
O Cell Test........................................................................................142
CONCRETE WORKS
Cement..............................................................................................145
Physical requirement of Cement...........................................................149
Mineral Admixtures.............................................................................150
Fly ash..........................................................................................150
GGBFS..........................................................................................154
Micro silica& Metakoline.................................................................154
Aggregates.........................................................................................155
Mechanical Properties....................................................................158
Grading Requirements...................................................................159
Mixing of water...................................................................................161
Admixture...........................................................................................162
Concrete............................................................................................163
Grades of concrete........................................................................164
Exposure conditions.......................................................................165
Batching.............................................................................................168
Mixing Time........................................................................................170
Transporting Concrete.........................................................................171
Planning.............................................................................................172
Compaction.......................................................................................173
Vibration............................................................................................173
4
Points to remembered in Compaction..................................................174

Finishing............................................................................................175
Curing...............................................................................................177
Common defects in Concrete..............................................................179
Types of Surface defects.......................................................................180
Special concrete..................................................................................186
PRESTRESSING
Introduction........................................................................................187
Definition...........................................................................................187
Advantages of Prestressing..................................................................188
Application.........................................................................................188
Materials management.......................................................................189
Reference Standard & codes................................................................191
Elongation & Modified Elongation Calculations....................................192
Jack Pressure calculations....................................................................192
Losses in Prestressing..........................................................................193
Properties of HT strand (IS: 14268-1995).............................................193
Methodology of Post Tensioning works.................................................194
Prestressing Equipments......................................................................197
Tendon Profile.....................................................................................198
Case study.........................................................................................199
Photos................................................................................................201
Aluminium Formwork
Introduction
Formwork Drawings
Site will be provided with a set of formwork drawings which entailed the
followings: Shell Plan Layout
Formwork layout drawings,
Wall panel Layout,
Slab Panel Layout,
Starter Block Layout,
Corner Layouts,
Beam Panel Layout,
Soffit Layout,
Staircase Layout,
Bracket and Soldier layout,
Miscellaneous Layout which includes sunken portion, upstand portion
etc,
Elevations and sections drawings indicating the location of formwork
panels and component,
Typical Fixing Detail drawings,
Location of Box outs and Transfer Box out drawings for transfer of
Formwork, etc.
Worksite Management
Logistic
Prior to the arrival of the containers from the disembarking point to the
project work site; a Stock Yard is to be properly allocated and set up for
the unloading of the formwork material and accessories.
This Stock Yard should preferably be located at close proximity or within
the compound of the project work site, properly fenced up and security
6
shall be of up most priority due to the high residue value in the secondary
market for aluminum formwork material.
A Workshop area for maintenance of formwork material is recommended
to be set up at the project site to minimize the downtime in requisition of
replacement panels.
The proposed Stock Yard and Workshop area shall be flexible and readjustable to suit the working environment and project work site. As a
result of the far away Stock Yard or Workshop area the project progress
will affect the targeted construction cycle time. (Ref Layout Drg No.:
)
Upon arrival of formwork panels at Project Site, Site personnel shall ensure
that the panels are stacked and stored according to sizes and marking using
proper separator such as pallets for easy identification and allocation for
subsequent distribution. (Dry Mockup will be assembled as per schemes
at factory; this will eliminate the usual problematic discrepancies of odd
size panels which need to be fabricated at project site).
Manpower
BSCC - HQ shall provide the estimated manpower requirement for the
Project based on the quantity of formwork panels to be supplied to achieve
the required cycle time. This manpower requirement shall vary according
to the size of formwork use on the building.
However, the manpower requirement for other supplementary trades which
complement the formwork installation such as Mechanical & Electrical
(M&E) services and rebar works need to be taken into consideration also.
A joint effort of all operations from formwork installer, rebar, plumbing,
electrical and concreting workers need to be synchronized to achieve the
required cycle time.
Segregation and systematically allocation of duties for each formwork team
are required in ensuring optimization of productivity. Hence, each team
shall be delegated or assigned to do specific job tasks on a daily basis to
resemble a manufacturing production line. However, due consideration
should be used in determining the level of experience and compatibility of
persons when allocating tasks to minimize the risks.
Safety
Control measures should be taken to identify and minimize the hazards
associated with work involving the assembly and dismantling of formwork
equipment such as falls from height, slips, falling objects, noise, dust and
manual tasks.
The external working brackets/platforms or scaffoldings should not be
used to stack materials or equipment. This will lead to the persons working
on it expose to additional hazards in relation to trips and slips or collapse
of the external working brackets / platforms or scaffolding.
Minimize the working heights for persons performing the assembly and
dismantling formwork.
Mixing of formwork components should be avoided to prevent unsafe
installation such as mixing pins and braces which may lead to collapse of
the formwork.
Do not allow drop stripping of formwork as it is an unsafe practice.
Partially assembled or dismantled formwork should be secured during
break time to prevent against overturning or collapsing due to strong wind
or accidentally / unintentionally knock over by workers.
Electrical safety should be implemented for the safe use of electrical
equipment.
Protruding flat ties or projecting nails should be removed immediately
with appropriate tools at dismantling stage.
Use of personal protective equipment by all persons working at work
areas (such as safety hardness, safety helmets, eye protection etc) should
be strictly implemented.
Accessories & Tools
Accessories (10%) extra will be supplied for the assembly and dismantling
of the formwork panels.
Sufficient tools required for assembling and dismantling will also be
supplied as per the attached list.
Assembly Process
Setting Up Level & Marking Of Position
The project surveyor shall mark based on the approved construction drawings
to ensure that the gridline and level of the foundation level is properly set up,
marked for walls, column etc. Leveling must be checked prior to commencement
of formwork installation to ensure accurate positioning.
Formwork Panels
Cleaning of the surface and side panel of the formwork after each usage
shall be done immediately using proper tools.
Ensure that all front and side panel of formwork is properly coated with
recommended Form release agent that prevents from sticking and concrete
buildup aluminium form surfaces. It protects and prolongs the useful lives
of the aluminium formwork.
The following precautions shall be taken when applying the Formoil on
the aluminium panels.
The best results are obtained when a uniform application of Formoil is
applied immediately following stripping and subsequent cleaning of
the panels. Always ensure that the coated form surfaces are allowed
to dry prior to placing concrete.
Do not over apply. Excess Formoil can adversely affect performance
and should be picked up promptly with rags.
Prevent Formoil overspray from contacting reinforcing steel bars and/
or tensioning cables.
Installation Works of Rebar, M&E & Plumbing
The support works such as rebar, Mechanical & Electrical (M&E) and
plumbing are to commence immediately once the set up is done. The
same is to be ensured before installing the Aluminium formwork.
The support works for the slab section commence after the slab formwork
panels are assembled.
Cover Blocks should be fixed on both sides of the rebar section for
positioning and eliminate the rebar from resting on the surface of the
formwork panels.
9
Positioning of outlets for electrical switch boxes to its correct alignment can
be done by riveting the appropriate fit size mould to the formwork panels.
The electrical switch boxes are then securely cap to the fit size mould and
fasten by way of wiring to the formwork panels. Ensure that it is properly
secured to prevent grouting from building up in the switch boxes.
Assembly of Wall Formworks
Always commence wall erection from the external corner of the wall
section to ensure both joint external corner wall panels will support each
other for standing position. Pin and wedges are to be used to secure the
panels together. Always insert the pin from the inside out for easy removal
of pin after concreting.
The formwork panels wall positioning is securely placed on the marked
gridlines and level by way of fixing timber stoppers at the base of the
outer side of the formwork panels at interval of one (1) meter. This would
ensure that the formwork panels are not disposition during the concreting
process.
Once the initial wall corner panels are assembled, place the wall corner
panels on the allotted set up position.
Commence to erect simultaneously the balance of the wall panels from
either side of the external wall panel.
Proceed to assemble the internal wall corner. Place these panels into the
correct position on the lines which were set up by the surveyor. Proceed to
assemble the balance of the internal wall at both sides.
The internal and external walls are to be held together by flat wall tie with
wall tie sleeve and PVC cover. These wall tie sleeve and PVC cover are
to be cut for the exact length of the wall thickness. Flat wall tie are to be
coated with the Form Oil before each usage.
To determine and achieve the vertical accuracy of the formwork panels
assembled before concreting process, several methods such as plumb
bob, spirit level, theodolite equipment etc can be used. The simplified
method of using a plumb bob with a string attached to it which is then
suspended from the upper part of the formwork panels is used as a guide
to determine the deviation from the vertical alignment of the panels.
Additional wall panels or starter blocks (kickers) are fixed on the external
wall panels in accordance to the required height for the formation of the
10
slab concrete. Check to ensure that the verticality of the Starter Blocks
(kickers) is correctly aligned.
The Starter Blocks (kickers) shall remain at its position for the subsequent
forming of next level wall.
Assembly of Beam & Slab Formworks
Fix the slab corner on top of the wall panels with round pins and wedges.
The position of the pins should be from top down to ease the dislodging
process.
The prop length and prop head is to be connected together for beam and
slab support.
Alu span mid beam and Alu span cantilever end beam are connected to
the Slab prop head using Beam Splice Bars. They are connected together
by long pins and wedges at bottom section.
The Aluspan mid beam sections are accurately position to enable the slab
panels to be connected systematically.
Commence to assemble the slab panels from the corner section of the
slab. Subsequently, fixed the whole slab area by pinning the slab panels
together with the Aluspan mid beam.
Assembly of External Working Brackets
External working platform brackets are used to provide a work area at the
external wall section.
Once the first level is completed and external formwork panels are
removed, fix the external working brackets to the first floor level at position
slightly below the kickers which are fixed on first floor external slab.
The external working brackets are secured to the external wall section
from the inside using tie rods, nuts and bolts.
Once all the external working brackets are put in place, timber planks
and strips are placed on the floors and railings respectively to create an
external working platform for the assembly of the subsequent level of the
external formwork panels and kickers.
Another set of external working brackets are later fixed on the subsequent
level using the method as prescribed above.
Once the subsequent level of external formwork panels are fixed, the
11
external working brackets at one level below are removed and moved to
the subsequent level. This process is repeated until the completion of the
subsequent floors.
Identification of Formwork Assembled
A numbering sequence / stenciling shall be given for each panel and is
identified in accordance to unit area such as living rooms, Kitchens, Bed
rooms, bathrooms, common areas etc.
Color identification scheme while numbering on each section or area will
also eliminate the confusion that may arise due to the size. It can be
identified such that Blue is for Room 1, Red is for Room 2, Green is for
Living area etc.,
By practicing the use of numbering system in combination with the color
identification scheme, it have been proven to avoid confusion and assist
in the process of identification of panels position once they are transferred
to the next level/floor.
CONCRETING PROCESS
Pre-Check Before Concreting
Ensure that the position of the walls and column formwork are in
accordance with the set up marking.
Check to ensure correct spacing of props for slab formwork.
Check the verticality and horizontality level of the wall and slab panels
respectively.
Ensure that all pins, wedges and ties are properly secured and tightened.
Re-check the opening such as door and window panels are correct.
Re-check all propping stands to ensure its height are in accordance to
drawings.
Adequate bracing (if necessary) to ensure stability.
Ensure cover blocks are placed correctly.
Monitoring During Concreting Process
Ensure site coordinators are available and on stand-by during the
concreting process.
Always ensure that concrete pouring is distributed evenly throughout the
12
wall sections before commencing to cast the slab level areas. This is to
prevent loading pressure on the formwork panels due to uneven casting.
Recheck the areas whenever cement slurry leakage is noted to determine
the cause of it. Remedy work should be done immediately to ensure the
concreting process is not affected.
During concreting, always ensure that immediate step is taken to remove
/ clean all the excess concrete that is stuck on the back of the formwork
panels. Non removal will result in the formwork panels getting too heavy
and also the scrapping task after the concrete has dried up becomes more
tedious.
13
Dismantling Process
Dismantling of Wall, Column & Beam Formwork
Formwork panels shall be removed without damaging the concrete.
Reinforcement Bars or other tools shall not be used as a lever against the
concrete in removing the formwork panels. Only panel puller shall be
used for removing the wall panels.
The appropriate time for the stripping of formwork panels will vary
according to the environment and type of concrete used. The formwork
panels of the wall, column and beam section can be usually dismantled
after 12 hours. However, this process shall subject to approval of the
project structural engineer after taking into consideration the grade of
concrete used, additional props stand ordered, etc.
lways ensure that the wall section panels are removed first follow by the
A
column and beam sections.
For precautionary step, ensure that formwork panels are removed
systematically and due care is to be taken to prevent any damages to the
formwork panels and also finish surface of the concrete whenever possible.
or safety reason, ensure that no workers are facing the pin and wedges
F
when removing using hammer. Pin and wedges removed are to be
collected and placed in containers to minimize lost and replacement.
he dismantle formwork panels shall be transferred to the next level/floor
T
for subsequent assembly process via the slab opening or staircase areas
in an orderly manner and to the appropriate section/area immediately.
This will eliminate the confusion and congestion in the dismantling area
or level as a result of too many dismantled formwork panels lying on the
floor area.
s the formwork panels are pre-numbered and if color identification
A
scheme is implemented, the transfer of panels can be determined and
planned ahead according to the various sections / areas of one level/floor
to the subsequent level/floor.
lways ensure that all the formwork panels are to be properly cleaned
A
and applied with the Form release agent to protect the surface of the
formworks before re-used.
14
or the external wall section, the Starter Blocks (kickers) on the upper
F
portion of the floor level shall remain intact to support and align the
next level/floor of formwork panels that are going to be assembled.
The assembly of the external formwork panels can be done by using the
external working platforms that are fixed to the wall areas.
Dismantling of Slab Formwork
he appropriate time for the stripping of formwork panels will vary
T
according to the environment and type of concrete used. The formwork
panels of the slabs section are usually dismantled after 36 hours. However,
this process shall subject to approval of the project structural engineer
after taking into consideration the grade of concrete used, additional
props stand ordered, etc.
he Aluspans mid beams / end beams have to be removed first after
T
dismantling the wall panels. Proceed by removing the long pins and
wedges on the joint bars for the end and middle beams. However, the
prop lengths are to remain undisturbed during this process to lend support
for the weight of the concrete slab.
here shall be 2 sets of prop lengths to support the concrete slab. The first
T
set of the prop stands will only be removed when the assembly of the third
level/floor commences and also upon approval and consultation with the
project structural engineer.
roceed to dismantle the slab panels by commencing from the end of the
P
slab area. Once the slab panels are dismantled, continue to remove the
slab corners.
Removal of Flat Wall Tie & Wall Tie Sleeve
Flat wall Ties are used for the purpose of ensuring the thickness of the walls
and column are consistent. Flat wall ties are to be removed by using special
called Wall tie remover / extractor.
Subsequently, proceed to remove the wall tie sleeve which is embedded in the
walls and columns section by using nose player.
15
Assembly Process
Sequence No. 1
Form Release agent (Solvent based) to be applied on the surface of all the
panels before the assembly process.
16
Assembly Process
Sequence No. 2
Outer Corner is fixed to External Wall Corner panel by round pin and
wedge.
17
Assembly Process
Sequence No. 3
Inner Corner is fixed to the Internal Wall panels by round pin & wedge. The
Internal and External Wall Panels are hold by Flat Tie with Tie Bar Shield in
between the panels.
VERTICAL CORNER INTERNAL
18
Assembly Process
Sequence No. 4
Repeat Sequence No. 3 to complete the assembly of both the Internal and
External Wall Panels.
19
Assembly Process
Sequence No. 5
Install Slab Corner on the top portion of the Wall Panels with round pin &
wedge.
Slab Corner Internal
20
Assembly Process
Sequence No. 6
Aluspans mid beams / end beams and Prop head are combined by Beam
splice bar with long pin and wedge at the bottom section.
BEAM SPLICE BAR

Aluspan cantilever
BEAM SPLICE BAR

Aluspan
21
Assembly Process
Sequence No. 7
Start the assembly of the Slab Panels from the Slab corner Internal.
Subsequently, fill out the whole slab area by pinning the slab panels together
with the Aluspans (Comprises of Aluspans and cantilevers). Mid Beams / End
Beams
Slab corner Internal
22
Assembly Process
Sequence No. 8
Additional Wall Panels (or Kickers) are fixed to the external Wall Panels to raise
to the appropriate height to contain the slab concrete when it is poured.
ADDITIONAL WALL
PANEL / STARTER
BLOCK
23
Assembly Process
Sequence No. 9
Upon completion of the installation and fixing of the Wall and Slab Panels,
a numbering sequence will be made for each of these panels with colour
identification scheme to differentiate each of the unit area such as bedrooms,
living room, bathroom etc. This numbering and colour identification scheme
will ensure that each panels can be determined as to their exact location once
they are tansferred to the next level for installation.
Sequence No. 10
Always ensure that wall ties, pins and wedges are properly installed and
secured before pouring concrete into the forms. Ensure that concrete pouring
is distribute evenly throughout the Wall Panels section before commencing to
cast the slabs level area.
24
Dismantling Process
Sequence No. 1
After 12 hours, remove the Internal Wall panels by knocking out the wedges
and pins. The Wall Panels are to be moved to upper floor through the slab
opening as shown. The transferring of the panels should be done in a
systematically and orderly manner to ensure that the next cycle or level is not
affected. Since all the panels are numbered with different colour identification
scheme, these transfer process can be determined and planned in advance
according to section of the building such as Room 1, Room 2, Bathroom are
etc.
25
Dismantling Process
Sequence No. 2
After removing the External Wall Forms (the starter Block (kicker) should
remain undisturbed), the dismantled wall forms are moved to upper floor.
Access Scaffolding is use for transferring of external wall panels from the
ground floor level. For level 1 and above, an external working platform is
fixed to the external wall. The external wall forms from level 1onward shall
be supported by the kickers. (These steps are to be repeated from one floor
to another floor.)
Starter Block
Super plate
26
Dismantling Process
Sequence No. 3
After removing the Wall Panels, proceed to the Slab Panels after 36 hours
by removing the long pins and wedges on the joint bars the end and middle
beam section.
27
Dismantling Process
Sequence No. 4
Upon removing the Aluspans Mid Beams and Aluspan cantilevers End Beams,
the prop shall remained undisturbed during this process to support the
concrete slab.
28
Dismantling Process
Sequence No. 5
Proceed to strip the Slab Panels and transfer to the next level according to the
designated area and installation sequence.
29
Dismantling Process
Sequence No. 6
Strip the Slab Corner.
30
Dismantling Process
Sequence No. 7
Pull out Wall flat Tie using Wall Tie puller and remove the Wall tie sleeve using
Nose player.
Sequence No. 8
When the cube tests show that the slab concrete is sufficiently strong, the prop
together with the prop heads are removed and transferred to the next level.
31
Flow Chart for

Aluform Work at Site
FLOW CHART FOR ALUFORM WORK AT SITE:-
1a, 1b, 1c
If not suitable
2a, 2b
3a
If suitable
If not suitable
4a
6
7
7a
8
If work front is not ready
12
10
If work front is ready
11
13
14
23
15a
15
16a
16
19a, 19b, 19c, 19d
19
22
21
17
20
32
18
Activity for the Flow

Chart Numbers
1. Receive Aluform materials.

1a. Packing list, BOQ, and Formwork layout.

1b. Tools.

1c. Additional accessories.
2. Visual inspection.

2a. Packing list & schemes.

2b. Acceptance criteria.
3. Inform concern for any defects

3a. Details of report.
4. Collect modification details.

4a. Fabrication drawings.
5. Stock the material as per packing list.
6. Room wise segregation.
7. Dry mock-up.

7a. Schemes.
8. Room wise numbering for identification.
9. Dismantling of mock-up.
10. Setting out.
11. Shift to work location.
12. Shift to stock yard.
13. Actual assembly at work location.
14. Slab rebars & M&E works.
15. Final checking (Pre pour check)

15a. Check list.
16. Concreting.

16a. Pour card.
17. Post pour check.
18. Leveling and finishing.
19. De-shuttering

19a. Removing pins and wedges.

19b. Removing wall ties.

19c. Removal of wall panels.

19d. Removal of deck panels.
20. Cleaning of panels.
21. Fixing of working platforms with brackets.
22. Erection of Safety posts / rails.
23. Applying Form release agent.
33
Slipform
Introduction
Slipform has been accepted as a precise construction technique within a
comparatively short period of time an indication of its considerable popularity.
This popularity has in turn encouraged further research ensuring the adoption
of new methods and modern materials, which have firmly established
slipforming as an economical, rapid and accurate form of construction.
Now that it is properly developed, the technique can be applied to many
different forms of structure, including tapering formations with straight
or parabolic profiles incorporating constant reductions in wall thickness.
Traditional applications for slipforming are silos, chimneys, bridge piers,
water towers, special application like construction of pylons, lift core wall of
building, lining for tunnel shaft, framed structures etc.,
Principles of Slipform
Slipform construction, also referred to as sliding form construction, is similar
to an extrusion process. Plastic concrete is placed in the forms, and the forms
act as moving die to shape the concrete. Once the form has been filled with
fresh concrete and hardening has started the form is gradually raised by the
lifting devices on which it is suspended. The rate of movement of the form
is regulated, so that the forms leave the concrete after it is strong enough to
retain its shape while supporting its own weight. Pouring of concrete, tying of
reinforcement, fixing of openings/inserts etc are performed gradually from a
working platform.
An average sliding speed of 200mm an hour is common, rising to 300mm
an hour under the best conditions and 100 to 150mm an hour when large or
complicated structures are being slipformed.
Design Considerations:
The slipform should be designed so that the loads to which its various
component parts are subjected are uniformly distributed, and the yokes are
loaded as uniformly and axially as possible to avoid their overturning. The
jacks should not be located in wall openings as for as possible. The loading
should not exceed the lifting capacity of the jacks. The loads acting on slipform
can be classified as follows,
34
BASIC LOADS
Dead load due to the components
Live loads due to Concrete
Friction between form and concrete
Workmen
Materials
Machinery
Other installations
Auxiliary load due to the way of application of live loads,
Crowds of workmen
Piles of materials
Shocks produced by material unloading
Accidental Loads
Wind pressure
Adhesion between concrete and form due to long interruption.
Friction due to incorrect position of form
Failure of one jack
Extraordinary Loads
Breaking of certain members of the slipform
Failure of two adjacent jacks
Minimum concrete strength required for slipform application,
2
Kgf / cm 2 - when releasing the form.
Kgf / cm 2 - when coming out from the form.
20 Kg / cm 2 - after 24 hours since pouring.

200 Kg / cm2 - after 28 days.
35
Type of Slipform
The slipform can be broadly classified into,
Straight slipform.
Tapering slipform.
Slipform for special applications
Typical structures that are constructed using straight slipform technique are,
Silos
Cylindrical chimneys
Water tank shafts
Columns
Typical structures that are constructed using Tapering slipform are,
Conical chimneys
Ventilation stack
Tapered bridge piers
Typical structures that are constructed using Special slipform are,
Lift cores
Framed structures
Preheater building
RCC Pylons
Construction of block of flats, lifts and stair- well, bridge piers, preheater and
RCC pylons for boiler supporting structure using slipform techniques comes
under special applications because of their complex sizes, shapes and loads
to be lifted along with slipform, like walkway trusses, etc. which is essential
for construction.
Assembly Procedures
Stright Slipform
Position the vertical and horizontal reinforcement with correct cover.
Casting of the starter. (min: 150 - 200mm)
36
Check starter for the correctness in level and diameter.

Fix the inside and outside staging brackets/erect scaffold pipes, if
required.
Fix timber runners connecting the walkway brackets. / Level the surface
using cement mortar.
Check the level.
Tie the vertical and horizontal reinforcement upto shutter top height.
ark the position of inside and outside yokes in the starter, starting from
M
the tower location.
nsure that three sets of yokes are located in between two tower
E
verticals.
lign the panels and introduce steel washers at regular intervals to
A
maintain
4mm slope both inner & outer faces.
ix top and bottom waler pipe. Fix external supports, both horizontal and
F
inclined to align the shutter.
Fix filler panels.
Repeat the operation 10 to 12 for outside and make sure that washers are
introduced at the bottom of shutters to achieve 4mm slope towards inside.
ix the waler shoes, inside and outside yoke legs. Adjust waler shoe and
F
check the verticality on both faces
Keep timber supports between top & bottom walers at yoke location.
Align the form panel by external supports.
ix the yoke beam generally two numbers at the bottom and one number
F
at top.
Check the level of yoke beams with spirit levels.
Fix the inside and outside walkway brackets.
inish the final alignment by suitably adjusting the waler shoe bolts. Ensure
F
that all walers are touching the form panels. Provide packing wherever
required.
Fix the flying tie rod assembly and support the center rings. Ensure uniform
tightness is maintained in all the spokes.
37
Tapering Slipform
Position the vertical and horizontal reinforcement with correct cover.
asting the starter. (Provide pocket or pipe sleeve in yoke locations to
C
accommodate tapered sleeves )
heck starter for the correctness in inclination level and diameter. Chip
C
and finish the same, if required.
rect central tower using L&T HDT system and fix planks on the top after
E
aligning the top construction accurately.
Fix the centre frames with the help of scaffold pipes, if required.
re assemble the trusses and spiders after marking the location of inside
P
yoke leg, assemble with yoke legs, yoke beams, adjusting screws as per
initial setting diagram , erect them and provide support.
Check the level of truss.
ark the position of inside and outside yokes in the starter starting from
M
the tower location.
ssemble the panels along with
A
condition.
form supports with pre assembled
ix top and bottom waler. Fix external supports both horizontal and inclined
F
to align the shutter.
ix inside and outside consoles and upper outside console and fix
F
planks.
Fix the yoke beams at top & bottom.
Check the level of yoke beams with spirit levels.
Fix the top platform pipes with guard railings.
Fix the jacks & turnbuckle jacks and finish the hydraulic connections.
Test for leakage in the line and jacks and replace, if required.
Fix water level tubes & check the platform level. Adjust if required.
Check the the final adjustment as per the initial setting diagram.
Fix the handrails.
Fix the tapered sleeves & jack rods.
nergise the slipform before filling the form and removing temporary
E
supports.
38
tart the concreting after completion of all activities and checking the
S
availability of all materials as given in the planning for slipform.
Fix the inside and outside hanging scaffold and do the decking.
Tie the safety net.
Assembly of Stair Tower:

The verticality of the stair tower shall be checked only with plumb bob.
Stair tower shall be checked for verticality at every support location. If any
deviation is found it shall be corrected then and there, by adjusting support
length. The deviation in verticality shall not be more than 10mm for every
10M of height and maximum 50mm for the overall height.
CARE DURING SLIPFORM OPERATIONS:
1.
Uniform layer of concreting.
2.
Regular cleaning of shutters.
3.
Penetration testing of concrete, for setting time.
4.
Freeness of tapered sleeves.
5.
Periodical plumb readings.
6.
Adjustment for tilt & twists.
7.
Prevent overflowing of concrete.
8.
Maintain a free board of 100 mm.
9.
Uniform distribution of load on the platform.
10. Lowering of unwanted materials periodically.

11. Proper handling of lasers.
12. Cooling of jacks where the temperature is very high.
13. Protection of high pressure hose.
14. Protection of turnbuckle spindles.
15. Greasing of all moving parts / outside the shutters.
16. Ensure free movement of shutters, walers, intermediate form supports,
planks and handrails.
39
17. Consistent quality of concrete.

18. Periodical checking of concrete slump.
19. Fixing of required setting time for concrete based on slipping speed.
Dismantling Procedure
Stright Slipform:
1.
Provide coil nuts in the final layer of concrete approximately 300 mm

from top of concrete.
2.
Fix dismantling brackets, handrails, finish planking and transfer the load
of slipform assembly to the brackets.
3.
Remove the flying tie rod assembly and lower the same.
4.
Remove the inside and outside hanging scaffold and shift the planks to
the staging brackets.
5.
Remove the jacks and sleeves.
6.
Remove the yoke assembly, which consists of yoke legs,

and waler shoes.
7.
Remove inside & outside walers.
8.
Remove the wall forms, while removing the waler.
9.
Extract the jack rods and grout the holes.
yoke beams
10. Remove dismantling brackets after completing other works.

Tapering Slipform:
1.
Provide coil nuts in the final layer of concrete.
2.
Fix dismantling brackets, handrails, and fix the planks.
3.
Remove and re-locate the R.G.Hoist to the required location(if it is

there).
4.
Transfer the load of slipform assembly and main truss to the wall.
5.
Remove & re-fix the safety net with the temporary platform.
6.
Remove the inside & outside hanging scaffolding.

40
7.
Remove all the hydraulic hoses, manifolds and the jacks.
8.
Remove the intermediate form supports, spindles, turnbuckle, shutters,

form supports, wall thickness screws, radius screws and yoke beams.
9.
Remove inside & outside yoke legs.
10. Dismantle the truss assembly.

11. Extract the jack rods and grout the hole
12. Lower the materials then and there.
13. Remove the dismantling platform.
Slipform Reinforcement:
The progress of slipform is mainly determined based on the time consuming
for concrete pouring speed and reinforcement tying. if any delay in these
two the progress will affect drastically. As the space available for tying the
horizontal is restricted in slipform, it is very essential to plan all the activities
well in advance and to be prepared before starting of slipform.
The following points have to be considered while making the schedule.
The length of vertical/horizontal bars should be restricted to 5 mtr. due to
the constraints in lifting and handing at heights.
The diagonal bars around openings should be avoided.
Wherever stirrups are used it should be in 2 pieces only.
I t is not possible to have verticals in yoke locations and hence alternate
bars should be placed nearby.
herever concrete is taken through a chute the verticals below the chutes
W
have to be lapped with smaller lengths by means of welding.
The total requirement of reinforcement should be cut / bent and kept near
the slipform structure before starting slipform. The stocks should be kept with
proper tag for easy identification.
Refernce Standards And Codes
1. ACI 318- Building code requirements for reinforcement concrete.
2. ACI 304- Recommended practice for measuring, mixing, transporting
and placing concrete.
41
3. ACI 313-77 R83 - Recommended practice for design and construction

of concrete bins, silos and bunkers for storage of granular materials.
4. ACI 347-78 - Recommended practice for concrete formwork.
5. ACI 313-77 - Allowable tolerance.
6. ASTM C 403-70 - Penetration resistance method of concrete setting.
42
Summary of Labour
Productivity Norms
Sl.
No.
Type of Work
Unit
Norms
In M.Hrs
Erection of Access Tower (2.5 X 2.5 M)
RM
32
Dismantling of Access Tower (2.5 X 2.5 M)
RM
15
Erection of Stair Tower (2.5 X 2.5 M)
RM
16
Dismantling of Stair Tower (2.5 X 2.5 M)
RM
Straight Slipform Assembly
YOKE SET
75
Straight Slipform Dismantling
YOKE SET
55
Slipform Operation - Straight Slipform
M2
1.22
Assembly of Pre-Stressed Silo
YOKE SET
92
Slipform Concrete - Manual
22
10
Slipform Concrete - Rmc With Pump
M3
15
11
Slipform Concrete - Rmc With Hoist
M3
25
12
Slipform Reinforcement - Straight Slipform
MT
65
13
Extraction of Climbing Rod
RM
0.34
14
Taper Slipform Assembly - Upto 24 Yoke Set
MT
56
15
Taper Slipform Assembly - 16 To 48 Yoke Set
MT
49
16
Taper Slipform Dismantling - Upto 24 Yoke Set
MT
49
17
Taper Slipform Dismantling - 16 to 48 Yoke Set
MT
46
18
Re-Assembly of Slipform - Taper Slipform
MT
78
19
Re-Assembly of Slipform - Straight Slipform
YOKE SET
90
20
Slipform Operation - Taper Slipform
2.45
21
Slipform Reinforcement - Taper Slipform
MT
90
22
Erection of R.G.Hoist
NOS.
827
23
Re-Location of R.G.Hoist
NOS.
1365
24
Dismantling of R.G.Hoist
NOS.
675
25
Pre-Stressing Works in Silos
MT
170
Note: The productivity norms will vary based on volume of work involved and number
of structures to be constructed in the project.
43
Slipform Planning
The execution of slipform job requires a complete and detailed preparation
as many simultaneous and successive operations are involved. The method
of construction, preparation of scheme drgs., calculating the requirement of
slipform materials, equipment, tools & tackles, consumable, manpower etc
needs thorough planning.
It also involve mix design, admixtures to be added for the concrete,
reinforcement around openings and planning for other related works on the
slipformed structure.
Straight Slipform
On large site with several structures built with the same slipform, planning
includes
Work below slip form level
Detailed programme for the wall
Work involved in intermediate floors, if any.
Embedment/ pockets and other installations during slipform
Slipform Materials
The number of yokes for each silo is calculated based on the diameter of the
silo. The yoke to yoke distance is normally kept between 1.25 and 1.35 m.
Once the number of yokes required is calculated the list of materials can be
prepared from the master list. The requirement of jack rods depends on the
height of structure. Always keep 5% extra material as spare.
The length of yoke beams = Wall thickness + 1000 mm.
Normally 2Nos. Yoke beams at the bottom and 1 at the top are fixed.
Wherever yokes are used for supporting some lifting arrangements, there the
top yoke beams also shall be 2 no back to back.
Slipform Equipment:
The capacity of Jacks to be deployed is depends on the following loads:
Basic Loads:
Dead weight of yokes,
44
Dead weight of Concrete lifting arrangements

Weight of Platform with 40thk plank
Weight of wooden Runners 125*75mm
Total Dead Load
=X
Live Loads
Live load over platform @ 200kg/sqm
Weight of Concrete 0.5 cum
Weight of Steel (reinforcement, jack rod stacked on platform)
Weight of Equipment
Total Live load
Frictional forces @0.173kg/m (length along the wall sides)
Total Load on Slipform
L = (X+Y+Z) * t
Required Jacking Capacity (W) should be with 1.4 factor

Note:- Jack shall not be loaded more than 80% of its capacity.
Concrete Equipment
The quantity of concrete required per meter height should be calculated
first. The slipping speed can be assumed based on the quantity of concrete ,
reinforcement, pre-stressing and other related items. Rate of rise depends on
the above and setting time of concrete. Once the slipping speed is assumed
the concrete requirement per shift can be calculated.
Once the quantity per shift is known, with 25% spare capacity, the size and
number of mixing and lifting equipment shall be decided.
Consumable:
The standard list of consumable is given along with master material list. The
quantity of electrodes, gas, grease, oil etc. can be given approximately. The
45
wire rope required for hoisting to be calculated separately based on height of

the structure.
Timber Requirement
The requirement of timber is for the following areas.
1) Working platform
2) Masons platform
3) Runners for supports
4) Planks for the bracket platform if assembly is taken up from higher

elevation.
Working Platforms
Timber platform consisting of four parts
a) Supporting runners 5x 3x7 long & 6 long
b) Wooden planks 6 x 1 x 6 long.
c) Toe board
size: 4 x 1 x 6 long
Manpower Requirement:
The requirement of labour for various activities can be calculated based on the
productivity norms, site conditions and type of structure.It is preferable to engage
one single agency for the entire slipform works in a project to have better control
over productivity and also optimum use of workmen with multi skill.
46
Tunnel Form
Description of Half Tunnel Form
47
48
49
50
51
52
53
54
55
56
57
Movement of Formwork
58
59
60
Kickers
61
62
Ties
63
Protection Platforms
64
65
66
Aluminium formwork
Refurbishment
A) Process involved
a) Manual cleaning
A working table to be made and the Concrete lumps, dirt shall be cleaned by
the scrapper and wire brush.
67
a.1) Tools Required

Ball Pein Hammer
Chisel
Scrapper
b) Machine Cleaning
Side rails are cleaned with GQ4

Grinding Machine, 4 circular
buffing wheel.
b.1) Tools Required

GQ 4 Grinding Machine
4 circular buffing wheel
6 RUBBER BACK UP PAD
c) Dent Removal
Remove the Dents if any in the

panel using a hammer and a
flat base plate. Make sure that
no point contact is there during
this process.
68
d) Welding
After removing the dents,

inspect the panel for any
cracks in the welding joints.
If found it shall be welded.
d.1) Tools Required

TIG Welding machine
Welding coil spec :Aluminium filler wire 1.2 mm. Er 5356. Make: Indaco
e) Surface cleaning
Surface cleaning shall be

done with the sander disc,
ensure that smooth rendering
only is done.
69
e.1) Tools Required

AG7 & AG4 GrindingMachine ( RPM 5000)
Sander Disc (80/120 Grade)
f) Lacquering and Stenciling
Brushing viscosity of lacquer can be 30 sec. Surface to be touch dry with in 10

min of application. Allow over night and use. Thinner- MCC 2507.
Safety items
Hand gloves
Nose mask
Ear plug / ear muff
Apron
Goggles white
70
Plywood
Plywood is an important commodity which plays a key role in the formwork
both in terms of quality and cost (10-13% of formwork cost). The finish of
the concrete surface where plywood is used as sheathing members is purely
dependent on the quality of the plywood. Plywood is a manufactured wood
made up of thin sheets of woods and compressed together with a glue which
gives higher strength when compared to a normal wood.
Indian government has put stringent rules for cutting of wood which has
initiated the local ply manufactures to import the logs (poplar and birch wood)
from various foreign countries for the production of plywood. The performance
of the plywood (for formwork application) is mainly based on the glue which
they use for binding (mostly wood species used by all the manufactures are
common).
Plywood shall be tested at site premises before accepting. The testing facilities
are established in all major projects. Incase if the same is not available
respective site representative can contact the Cluster BSCC in charge for
extending the support.
Plywood procurement is centralized in order to deliver a quality product to the
projects at a competitive rate.
Plywood request format shall be filled and sent to the respective cluster BSCC
in-charge for clearing the procurement. Cluster BSCC in-charge will in turn
take concurrence from Head BSCC.
Now about 60 to 70% of the plywood requirements for the projects are serviced
from china and the following
are the details pertaining to the
same
Item Code 765610020
Repetitions 8 to 10
Price approx 20% cheaper
than domestic ply
Delivery period 60 to 65 days
71
72
Form Release Agent

Approved Form Release Agents
Its a management decision that apart from these solvet based form release
agent other products cannot be used until unless it is approved by Cluster /
HQ BSCC.
73
Formwork Lift
A system which complements the ability of Table form to do faster construction.
It is turning out to be one of the most important equipments which will be
extremely useful in improving the functional aspect of L&Ts trademark Table
form System. Till now, our Table form System was totally dependent on Crane,
especially while shifting the Table vertically from one Floor to the next. RCS
would not only help in drastically reducing this dependability on Crane but
also have a positive impact on the Labour Productivity subsequently helping in
reduction of Cycle time. Though the system was procured from the formwork
supplier the self climbing equipment was indigenously developed by BSCCHQ which further eliminated the crane requirement for floor to floor shifting
of RCS.
A project site will be debited with a internal hire charges of ` / Month
Cycle time
Labour Productivity -
74
ACS - Automatic Climbing System

Self Climbing System ACS - Fields of Application
Self Climbing System ACS
Self Climbing System ACS - Hydraulic System
75
Hand tools required (work place)
76
ROLES & RESPONSIBILITIESOF FORMWORK

ENGINEER AT SITE
1.
Preparation of Formwork programme based on the overall construction

programme
2.
Finalization and coordination of Shuttering Scheme
3.
Ensuring effective and proper utilization of shuttering and staging

materials
4.
Planning and allocation of materials / labour / Plant & machinery for

formwork activities in coordination with concerned persons at site
5.
Educating sub-contractors on System formwork
6.
Making mock-up of various System formwork
7.
Periodical reconciliation of formwork materials
8.
Preparing S-6 A schedule (requirement / release) and sending the same

to Cluster Office
9.
Preparing stock statement of formwork materials both in Units and in

Nos., with area of shuttering done category-wise, Plywood / Timber
procured during the quarter / till date and Productivity report.
10. Maintain close interaction with stores and site people for proper
accounting of materials
11. Despatch and receipt notes to be sent to Cluster Office
12. Making of purchase requisition for Plywood and Timber after thoroughly
analyzing the number of repetitions
13. Receipts of plywood / formwork materials to be acknowledged after
quality checks to Cluster Office on monthly basis
14. 100% materials reconciliation at the end of the job
15. Looking after pre-despatch maintenance
77
16. Ensuring that despatched materials are in usable condition.

17. Sending monthly reports to Cluster office.
ROLES & RESPONSIBILITIESOF SITE FOREMAN / CHARGEHANDS
1.
Material Accountability right from the materials receipts at site to despatch

to other site after the completion of the job.
2.
Small items have to be issued to the sub contractors from stores and
make them responsible for those items. For their sake, tool box can be
issued. These items have to reconcile after the completion of the job.
3.
Proper usage of the formwork materials and avoid the misuse (using
bracing as leverage) of the same.
4.
Ensure proper house keeping at site as well as the maintenance

(greasing / oiling after deshuttering etc.) of the formwork materials
5.
Deshuttering right on time to achieve maximum number of repetitions of

formwork materials.
6.
Optimum use of nails in H beam.
7.
Quality in works carried out at site so that tolerance should within

tolerance limit.
8.
Formwork labour productivity should be monitored closely to achieve the

management goal.
9.
Training of Labour and Sub contractor workmen at site either by mock

up or classroom programme by drawing sketches.
10. Adoption of safety standards while working by fully equipped with

PPE and using the complete system at site (do not miss any bracing /
connecting pin / locking pin etc.).
11. Use of stocking pallets.
System formwork functions, applications& Safety
78
1.Foundation formwork(All steel)

Functions/Salient features
1. All the components are made out of steel
2. No timber is used
3.
Easy to assemble
4. Higher labour productivity

5. High quality concrete surface finish
6. Suitable for side formwork of sub structures .
7. Capable of withstanding the concrete pressure of 10KN/sq.m
Sequences of assembly
1. Materials stocking near to layout
2. Cleaning and oiling
3. Layout marking
4. Floor forms positioning
5. Accessories fixing
6. Line and verticality checking
7. Concreting
8. Deshuttering
Safety appliances required
1. Safety helmet
2. Manila rope 20 mm or 25 mm
Safety precautions
1. During transporting and stocking the materials proper care has to be
taken
79
2. While lowering the materials from ground level to down level additional
care has to be taken
2.Wall/Column formwork
1. System can be done by Crane and Manual
2. Using standard component wide range of plan configurations are
possible
3. High strength tie system bear large concrete pressure and avoid load
bearing struts
4. Provisions for fixing scaffolding platform and alignment units built-in
5. Offsetseliminated producing good concrete finish
3. Layout marking/starter casting and layout checking
4. Panel positioning
5. Accessories fixing and alignment
6. Line, level and verticality checking
7. Concreting
8. Deshuttering
1. Safety helmet
2. Safety belt
3. Safetynet for taller structures
80
4. Manila rope 20 mm or 25 mm
Safety precautions
Crane operation
1. Sling capacity and quality of sling has to be checked
2. D Shackle capacity has to be checked
3. Experienced signal man has to be engaged for propersignaling to the
crane operator
4. Ensure that there is no loose material on the panels or platforms
5. Before lifting the panel, necessary pre checking has to be done on the
panels.
Manual operation
1. Use the necessary personal protection appliances such as helmet and
belt.
2. Use the proper tool for adjusting the panel height and line
3. Flex system
1. System can be used up to floor height of 4.40 mtr.
2. Removable folding tripods make selected individual props self
-standing
3. Flexibility in adjusting the individual prop height and spacing between
props
4. Components are easy to handle manually
5. Steel members can also be used for decking
7. Eliminating the skilled labour at site
81
2. Prop layout marking
3. Main Prop positioning with tripod
4. Intermediate props positioning with supporting head
5. Placing of fourway head, primary layer beam and secondary layer
beam
6. Levelingof beams with the help of props
7. Placing of plywood.
8. Levelling of seathing and checking
10. Concreting
11. Dismantling
12. Cleaning
13. Transporting and stocking
1.
Safety helmet
2.
Safety belt
3.
Safety net for taller structures whereever it is necessary
4.
Manila rope 20 mm or 25 mm wherever it is necessary
Safety precautions
1.
All the main props shall be fitted with folding tripod
2.
All the indermediate shall be fitted with supporting head
82
3.
Do not use tor steel in place of locking pin
4.
In ground level work , proper earth compaction and necessary bearing

below the prop shall be given
4.Heavy duty tower system -HDT

1.
Higher loading capacity of 250 KN and needs bracing at every 6 m in

height both horizontal directions with permanent other towers
2.
Can be assembled in plan dimensions of 1524x1524 mm and

2250x1524 mm, by choosing the type of bracing both configurations
with four legs of 62.5 KN capacity each.
3.
Height adjustments up to a minimum of 800 mm is possible by utilising

both top and bottom tower spindles
4.
Easy to obtain plumb using tower spindles
5.
Tower as a whole can be shifted(rolled) manually by attaching transport

devices to the legs
1.
Materials stocking near to layout
2.
Tower layout marking
3.
Frame fixing with necessary accessories at bottom and fixing of bracings

between the frames
4.
Placing of necessary accessories at top with U head and steel waler
5.
Placing of beam span and H-Beams
6.
Levelling of beams
7.
Placing of bottom/sheathing
8.
Leveling of bottm/sheathing
9.
Checking of levels and verticality

83

11. Concreting
12. Dismantling
13. Cleaning
1.
Safety helmet
2.
Safety belt
3.
4.
Safety precautions
1.
Every 6 mtr interval bracing has to be fixed with permanent structure or

tower to tower
2.
Ground level earth has to be compacted well for better loading
3.
Materials conditions has to be checked and badly damaged frames and

bracings to be avoided
4.
Do not use tor steel in place of locking pin
5. Stair tower
1.
Safe and convenient access up to 100 mtr height in the form of stair with
suitablebracing with bracing with permanent structures every 6 mtr
2.
Structural skeleton of HDT with a few additional accessories.
3.
Can be handled as a single unit with a crane
84
1.
2.
3.
Frame fixing with necessary accessories at bottom with foot plate , spring
locking pin and tower spindle
4.
Placing of 1.20 m frame with necessary bracing for one level
5.
Checking of level and verticality for one level
6.
Fixing of stair brackets ,grid iron ,connection angle , idermediate railing

and inner hand railing
7.
Every 6 mtr height necessary bracing with permanent structure
8.
Dismantling
9.
Cleaning

1.
Safety helmet
2.
Safety belt
3.
4.
Safety precautions
1.
Every 6 mtr interval bracing has to be fixed with permanent structure
2.
Ground level earth has to be compacted well for safe loading
3.
Materials conditions has to be checked and badly damaged frames and

bracings to be avoided
4.
Do not use coir string or binding wire in place of M 10 bolt and nut with
grid iron
5.
Do not omit any bracing

85
6. Access scaffolding
1.
Exclusively used for scaffolding purpose up to 40 mtr height braced at

every 6 mtr with structure
2.
Frames are lighter in weight and 1.0 mtr in width
3.
This provides free movement for workmen without any obstuction at all
levels
4.
Bracing 2H-225 serves as an essential bracing for stability as well as

hand rail on the face away from the strutures
1.
2.
3.
Frame fixing with necessary accessories at bottom with LD foot plate ,

spring locking pin and LD tower spindle
4.
Placing of frame with necessary bracing for one level
5.
Checking of level and verticality for one level
6.
Fixing of platform hanger and walk way 225
7.
Every 6 mtr height necessary bracing with permanent structure
8.
Dismantling
9.
Cleaning

1.
Safety helmet
2.
Safety belt
86
3.
4.
Safety precautions
1.
Every 6 mtr interval bracing has to be fixed with permanent structure
2.
Ground level earth has to be compacted well for safe loading
3.
Materials conditions has to be checked

and badly damaged
frames,walkway 225 and bracings to be avoided
4.
Do not use coir string or binding wire in place of Platform hanger
5.
Do not omit any bracing
7. Lift shaft formwork

1.
Provides a platform for shutter and workmen inside the closed area of
liftwell and a deshuttering mechanism for stripping of formwork without
dismantling the panels and seathing
2.
Panels can be lifted integrally in deshuttered position along with platform

and erected for next pour
3.
A few components are required in addition to all components of wall//

column formwork
1.
2.
Erect the platform in the pocket loations in the inside wall face with
climbing pawl arrangements
3.
Level the platform with the help of bolt given in the climbing pawl
4.
Erection of inner wall panels with the necessary accessories including tie
arrangements
87
5.
Erection of outer panels with necessary accessories
6.
Checking of dimensions,levels and verticality
7.
Concreting
8.
Releasing of inner panels for minimum of 20 mm on all the four sides
9.
Lifting of inner panels with platform for next level
10. Lifting of outer panels

1.
Safety helmet
2.
Safety belt
3.
Safety net for taller structures where ever it is necessary
4.
Manila rope 20 mm or 25 mm where ever it is necessary
Safety precautions
1.
Sling capacity and quality of sling has to be checked
2.
D Shackle capacity has to be checked
3. Experienced signal man has to be engaged for Proper signaling to the

crane operator
4. Ensure that there is no loose materials on the panels or platforms
5. Before lifting the panel , necessary pre checking has to be done on the
panels.
6. Ensure the gap before lifting the inner panel platform
8.Framed formwork Frami

1.
Sturdy and torsion proof hollow sectioned steel frame

88
2.
Hot-dip galvanished for high Durabilty
3.
High grade 15 mm thick film coated sheathing for high wear resistance
4.
Easy to fasten accessories
5.
Integrated handles for easier handling
6.
Permissible concrete pressure on formwork 40 KN/sqm
7.
Can be used for foundation , column and wall
1.
2.
Place the panels with all the necessary accessories as required
3.
Check the dimension,level,line and verticality
4.
Concreting
5.
Releasing of inner panels for minimum of 20 mm on all the four sides
6.
Lifting of inner panels with platform for next level
7.
Lifting of outer panels
8.
Cleaning and oiling

1.
Safety helmet
2.
Safety belt
3.
Safety precautions
1.
Provide the tierod only where the given the provision is given
2.
Do not omit any components
3.
Framiadj strut 260 is to be anchored properly

89
9.Climbing formwork
1.
Large area form work can be taken up
2.
Any height is possible
3.
High degree of safety as on the ground
4.
Faster and economical
5.
Can be used for inclined structures also
6.
Formwork is safely anchored to concrete at all times
7. Simple system of working platforms

1.
Safety helmet
2.
Safety belt
3.
Safety precautions
1.
Platform timbers should be free from cracks ,fungus attack and dead
knots
2.
Hand rails pipes are to be fixed properly
3.
Stop anchor threaded length shall be 55 mm inside the anchor cone
4.
Climbing cone threaded bore length shall be ------
5.
Plat form shall be free from gap between timber joints
90
REINFORCEMENT WORKS
Category of Reinforcements
Carbon steel bars (plain and deformed).
Cold reduced plain and deformed steel wire fabric.
Stainless steel bars and fabric.
Galvanized carbon steel bars and fabric.
Epoxy coated carbon steel bars.
Fiber Reinforced Polymer (FRP) rebar- [Non steel reinforcement]
Reference Indian Standards:
IS 1786 - 2008 - Specification for High Strength Deformed bar and Wires
for Concrete Reinforcement.
IS 432 PART 1- 1982 - Specification for Mild steel and Medium tensile
steel bars and hard drawn steel wire for concrete reinforcement
IS 432 PART 2 -1982-Specification for Mild steel and Medium tensile steel
bars and hard drawn steel wire for concrete reinforcement.
IS 2502 -1963 - Code of practice for Bending and Fixing Bars for Concrete
Reinforcement.
SP 34 -1987 Hand book on Concrete Reinforcement and Detailing
Reference International Standards.
BS 4449 Carbon steel bars for concrete.
BS 7295 Fusion bonded epoxy coated steel
BS6744 Stainless steel
BS 4483 Steel fabric
BS 4482 Hard drawn wire
BS 8666 Scheduling dimensioning, bending and cutting of steel
reinforcement for concrete - Specification
ASTM A 615 for carbon steel rebar.
ASTM A 706 for seismic rebar.
ASTM A 955 for stainless steel rebar.
ACI 440 for FRP bars
DIN 488 Reinforcing steels
91
How to Calculate Hook & Bend Allowance
REBAR TYPE
Bar Diameter,
d 25mm
k
Value
Hook
Bar Diameter,
d > 25mm
Bend
k
Value
Hook
Bend
Mild Steel
9d
5d
11d
5.5d
Medium Tensile Steel
11d
5.5d
13d
6d
Cold Worked Steel
13d
6d
17d
7d
Note:

All the Value is to be rounded off to nearest 5mm.

If the calculated result is<75mm, then take the result as 75mm.
92
Calculated Hook & Bend Allowance:

Hook Allowance (H)
Nom
inal
Size
of
Bar
(D)
Mild Steel
Min
Rec
om
md.
75
Medium
Tensile
Steel
Min
Rec
om
md.
75
75
75
10
Bend Allowance (B)

Cold
Worked
Steel
Min
Rec
om
md.
75
75
90
90
12
110
16
Mild Steel
Min
Rec
om
md.
75
75
105
110
130
145
20
180
22
Medium
Tensile
Steel
Cold
Worked
Steel
Min
Rec
om
md.
Min
Rec
om
md.
75
75
75
75
75
75
75
75
130
75
75
75
155
75
75
75
175
210
80
90
95
220
260
100
110
120
200
240
285
110
120
130
25
225
275
325
125
140
150
28
250 310 310 365 365 475 146 155 155 170 170 195
32
290 350 350 415 415 545 160 175 175 190 190 225
36
325 395 395 470 470 610 180 200 200 215 215 250
40
360 440 440 520 520 680 200 220 220 240 240 280
45
405 495 495 585 585 765 225 250 250 270 270 315
50
450 550 550 650 650 850 250 275 275 300 300 350
93
LARSEN & TOUBRO LIMITED -ECC DIVISION

QUALITY FORMAT
BAR BENDING SCHEDULE

PROJECT
AREA/BUILDING
:
:
DESCRIPTION OF WORK
DRG.REF .
:
:
MEMBER
BAR
NO.
DIA. OF
BAR
NO.PER
MEMBER
NO.OF
MEMBER
TOTAL
No. OF
BARS
CUT
LENGTH
DATE
TIME
:
NET
LENGTH
SHAPE
TOTAL Wt.
REMARKS :
SITE ENGINEER
REINFORCEMENT ENGINEER
94
CLIENT
95
96
97
Minimum Diameter Required for Bending Former
Bar diameter d (mm)
Bending Former
Minimum dia. (mm).
[As per IS 2502-1963]
for cold worked steel.
Bending Former
Minimum dia. (mm).
[As per BS-8666-2005]
48 (8d)
24 (4d)
64(8d)
32(4d)
10
80 (8d)
40 (4d)
12
96 (8d)
48 (4d)
16
128 (8d)
64 (4d)
20
160 (8d)
140 (7d)
25
200 (8d)
175 (7d)
28
336 (12d )
196 ( 7d)
32
384 (12d)
224 (7d)
40
480 (12 d)
280 (7d)
50
600 (12 d)
350 (7d)
98
Cross-Sectional Area and Mass of Rebar
NOMINAL SIZE( mm)
CROSS-SECTIONAL
AREA (Sq mm)
MASS PER METRE RUN

(Kg/m)
12.6
0.099
19.6
0.154
28.3
0.222
38.5
0.302
50.3
0.395
10
78.6
0.617
12
113.1
0.888
16
201.2
1.58
18
254.6
2.00
20
314.3
2.47
22
380.3
2.98
25
491.1
3.85
28
616
4.83
32
804.6
6.31
36
1018.3
7.99
40
1257.2
9.86
45
1591.1
12.50
50
1964.3
15.42
99
CHECKS
During procurement of Rebar
Check the brand isapproved or not.
Check Grade of reinforcement
Check the Quantity requirement and duration
If new vendor collect sample and check for conformity
On receipt at site
S
tack various diameter bars separately over wooden sleepers ( avoid
contact with soil)
Identify the stack with a tag number
Collect sample for test
inding Wires for tying rebar should be as per Technical specification /
B
BOQ [black soft annealed wire or GI wire of 16 gauge (1.6mm dia.)]
Rebar Stacking
100
TESTING OF REBAR
Sample collection
S
amples of 1 m length (quantity as per below table) taken randomly
per lot for each diameter.
Breaking of bars :
If rebars breaks during bending then check the carbon content of the lot.
Ensure bars of 25mm and above are free from cracking while bending 90
deg . If observed then straighten the bars again to know they are not
breaking. Collect samples and send for chemical analysis. Mark and identify
the lot till results available and lot is cleared of doubt.
Sample Testing on receipt at site
Samples of rebars collected from the lots received at site 2 sets of samples ( 3
specimens each) for 100 MT per Lot or Heat number and tested for mechanical
properties as above. If one sample fails to meet the requirement 2 additional samples
to be collected from the same lot and tested for conformity. If one specimen fails to
meet the physical requirement of Table 3 IS 1786 the whole lot is rejected.
Cover blocks
Cover blocks used shall be of same grade of concrete or made up of PVC
101
Check Rolling margin ( at site lab)
Weigh the mass (measure to a precision of +0.5%) of the rebar

samples.
Calculate the nominal mass
Mass of the sample

Actual length of sample
The nominal mass should satisfy the Table 2 of IS1786-2008
Mechanical Properties (To be tested at external Lab).

0.2% proof stress
Elongation
Tensile strength
Bend and Rebend test
Universal Testing machine (Used for

finding 0.2% proof stress, Elongation
& Tensile strength)
102
Rebar Mechanical properties should satisfy Table 3 IS 1786 requirements
For Bend and Rebend test there should be not any rupture or cracks visible
in the bent portion.
If any one of the test sample fails then collect 2 more sample of 3 Nos
each.
If any one sample fails LOT REJECTED.
103
Nominal Cover for Durability requirement:

Exposure
Nominal concrete cover in mm
Mild
20
Moderate
30
Severe
45
Very Severe
50
Extreme
75
Note:
main reinforcement up to 12mm dia bar for mid exposure the nominal cover
For
may be reduced upto 5mm.
nless specified otherwise, actual cover should not deviate from the required
U
nominal cover by +10mm
F or exposure condition severe & very severe ,reduction of 5mm may be made,
where concrete grade is M35 and above.
TIPS ON COVER:
DESCRIPTION
In no Case
Column
Bar
NOMINAL COVER
Less than Dia of Bar
Longitudinal
Reinforcing In no Case <40mm (or) Dia of Bar
COLUMN OF SIZE Up to 200 mm, 25 mm

whose reinforcing bar is <12mm
Dia.
Footings
Minimum Cover is 50 mm
TOLERANCE OF COVER
+10 mm
-0mm
ACTUAL COVER =
OF NOMINAL COVER
104
Material for Cover
Concrete cover blocks
PVC Cover block

105
Photographs
Plain Rebars
Deformed Rebars
106
Stainless Steel Rebar
Epoxy Coated Rebar:
107
Hot Dip Galvanised Rebar
FRP Rebar
108
Pre-fabricated cages
Rebar Tying machine
109
Splicing Methods
Lap Splicing
Welding
Mechanical Coupler
Precautions:
plicing should not be done at the area where the max. Bending moment
S
is more than 50% of moment resistance.
L ap splicing is not permitted for reinforcing bar > 32mm. (Clause
26.2.5.1(A), is 456 -2000 amendment 3).
Bars >32mm shall be welded or mechanically spliced.
hen two different dia. Bars is to be spliced, then the lap length calculation
W
is to be made on basis of smaller dia rod.
SPLICE-STRENGTH:
Description
Compression
Tension
Welded splice
100% of design strength 80% of design strength

of bar
of bar
Mechanical splice
100% of design strength 100% of design strength

of bar
of bar
Reinforcment couplers:
Classification according to IS Code (Draft):
Class L +H
Class L.
Different mechanical splicing systems based on type of reinforcment
coupler used:
Threaded couplers
Parallel threaded couplers
Tapered threaded couplers
Upset parallel threaded couplers
Coupler with crimped sleeve
110
Coupling with injected sleeve

Molten metal injection
Grout (or) epoxy resin injection
Butt splices
Welded couplers
Other patented type
Mechanical Coupler Photographs:
Couplers Based on Application
111
Classification of test for reinforcment couplers

Static tensile test
Slip test
Cyclic tensile test
Low cycle fatigue test &
High cycle fatigue test for L+H couplers only.
112
The above data is based on draft published by Indian Standard.

Reinforcement Binding
113
Hair Pin Tie:

The hair pin tie, the most secure
tie used on all good work for
fixing key bars and setting the
work securely, before infilling.
A most secure tie used on column,
beams and for tying key bars
before infilling.
Crown Tie:
The crown tie, again a most secure
tie, and is used in much same way
as the hairpin tie.
It has one further use that it can
be used to tighten bars together
that have a tendency to spring.
Splice Tie:
The splice tie, is used exactly as
the name indicates for joining
laps of splices in bars.
It is in fact, exactly the same as the
crown tie. And as the same useful
qualities
114
Welding of Reinforcments:
References Standards:
IS 9417-1989
SP-34(S&T)-1987
Lap Welding
Rebar Dia. Vs Electrode size
Sl.No.
NOMINAL BAR
DIAMETER (mm)
SIZE OF ELECTRODE,
MAX (mm)
Up to and including 10 mm
2.50
Over 10 up to and including 18 mm
3.15
Over 18 up to and including 28 mm
4.00
Over 28 mm
5.00
115
Quality Control Test on Welded Rebars

Samples of Lap welded joints to be tested for Mechanical properties like
Tensile. The failure should occur in the bars outside weld area and not on
the weld.
Samples of Butt weld joints to be tested for Tensile and Bend test. The failure
should occur in the bars outside weld area and not on the weld in tensile and
no sign of crack in the weld portion in bend test.
116
Precautions in Rebar Actvity:

Why is it important to bend the
bar around the correct radius?
The tighter the bend, the greater
the strains that are created in the
bar around the bend. The bend
diameters in IS 2502 -1963 have
been specified as they have been
demonstrated to give a good
balance between the need to
maintain ductility and provide
practical construction solutions.
The bend diameter requirements of
IS 2502-1963 are mandatory .and
they should not be compromised.
Why TMT Rebar should not be

cut with Flame?
If a TMT bar is heated and then
allowed to air cool, the hardened
surface will be lost and the strength
of the bar will approach that of the
core. This loss of strength is the
reason for the restriction on the
Flame /Gas cutting of TMT rebar
Cross-Section of TMT Rebar
117
Do not position laps in beam column junctions.

Do not position laps in the midspan of the beam at bottom
nsure sufficient chairs are

E
added at the right spacing
For the bars greater than 12 dia

the slope shall not be more than 1
in 6 dia as per the sketch. This is to
maintain the structural integrity.
118
Piling Works
119
What is a Pile?
Pile is a conduit through which load from the structure is transferred to soil
either by friction or by bearing or by both.
CLASSIFICATION
Concrete
Bored cast-in-situ piles
Driven cast- in-situ piles
Driven precast piles
Steel piles
120
Sheet Pile Vibro Hammer
Sheet Pile Driving With Guide Frame

Test on piles
Pile load test (vertical compression,lateral & pull out )
Pile integrity test (low strain dynamic test)
PDA test (high strain dynamic test)
Lateral dynamic test
Ultrasonic logging test
O cell load test method.
121
To be inserted in Page 88-(Continued from above)

FACTORS GOVERNING PILE SELECTION
FACTORS GOVERNING PILE SELECTION

SL.No.
FACTOR
BORED CAST
INSITU
DRIVEN CAST IN SITU
DRIVEN PRECAST
TECHNICAL CONSIDERATIONS
I
SOIL BEHAVIOUR DUE TO

CONSTRUCTION
PILE HEAVE
DOES NOT OCCUR
OCCURS
OCCURS
PILE LATERAL MOVEMENT
DOES NOT OCCUR
LOOSE MATERIALS AT PILE

TIP
DENSIFICATION OF SILTY
FINE SAND
DEVELOPMENT OF EXCESS
PORE PRESSURE
CAN OCCUR
CAN OCCUR
CANNOT BE CORRECTED
DOES NOT OCCUR
CAN OCCUR
CANNOT BE CORRECTED
DOES NOT OCCUR
OCCURS IMPROVES
SHEAR STRENGTH
WILL FORM RESULTS IN
WASHING OF CEMENT
SLURRY AND WASHING
OF PILE SHAFT
OCCURS IMPROVES
SHEAR STRENGTH
WILL FORM NO AFTER
EFFECT
WILL WASH CEMENT

SLURRY
UNAFFECTED
NECKING CAN OCCUR
NOT APPLICABLE
BOUND TO GET
SEGREGATED .QUALITY
CANNOT BE GURANTEED
QUALITY CAN BE
GURANTEED
FULL FRICTION AND END

BEARING WILL BE
MOBILISED
FULL FRICTION AND END

BEARING WILL BE
MOBILISED
CAN BE AFFECTED
NO EFFECT PROTECTIVE
COAT CAN BE APPLIED
d
e
SUB SURFACE WATER

CURRENTS
g
h
STRUCTURAL INTEGRITY
DUE TO TEMPORARY
CASING
QULAITY OF CONCRETING
II
PILE/ SOIL INTERACTION
III
CORROSION DUE TO
SULPHATE AND
CHLORIDES
DOES NOT OCCUR

MAY FORM DUE
TO TEMPORARY
CASING
RESULTING OF
CEMENT SLURRY
AT THE TIME OF
WITHDRAWAL
UNCASED BORE
WILL COLLAPSE
AND IN CASED,THE
CEMENT SLURRY
WILL GET WASHED
OFF
NECKING CAN
OCCUR
QUALITY OF
CONCRETE IN PILE
SHAFT CANNOT BE
GUARANTEED
IF BENTONITE IS
NOT CIRCULATED
CONTINUOSLY
SLUDGE CAN BE
FORMED AT
BOTTOM AND
SKIN FRICTION
MAY BE AFFECTED
CAN BE AFFECTED
122
SL.No.
FACTOR
BORED CAST
INSITU
DRIVEN CAST IN SITU
DRIVEN PRECAST
IV
NEGATIVE SKIN FRICTION
CANNOT
OVERCOME.NET
PILE CAPACITY
REDUCES.
CANNOT
OVERCOME.NET PILE
CAPACITY REDUCES.
CAPABILITY TO CATER FOR

HORIZONTAL FORCES
ADDITIONAL
REINFORCMENT
TO BE PROVIDED
WHICH MAY
CREATE PROBLEM
WHILE
CONCRETING
MAXIMUM RAKE
1H :8V
LONGER
ADDITIONAL
REINFORCMENT TO BE
PROVIDED. THIS MAY
HINDER CONCRETING
CAN BE EFFECTIVELY
REDUCED TO A VERY
LOW VALUE AT
MINIMUM COST BY
PROVIDING
BITUMINUOS COATING
SINCE CONCRETEIMG IS
DONE IN CASTING YARD
,ADDL REINFORCMENT
WILL NOT CREATE
PRBLEM FOR
CONCRETING.
SHORTER
VI
LENGTH OF PILE
MAXIMUM RAKE 1H :8V
MAXIMUM RAKE
1H :4V
SHORTER
PRACTICAL CONSIDERATIONS
1
HAIR LINE CRACKS DURING

DRIVING
N.A
N.A
PILE CONSTRUCTION AND

SUB SURFACE
INTERACTION OVERBREAK AND LOSS OF
GROUND
PILE CRUSHING AT HEAD
CAN OCCUR.BUT
PRECAUTIONS
AND SUPERVISION
CAN MINIMISE
THE PROBLEM.
N.A
DOES NOT OCCUR.
ACCURACY IN:
a) VERTICAL
b) RAKER
ACCURATE
NOT TOO
ACCURATE
ACCURATE
ACCURATE
MAY OCCUR DUE TO

INADEQUATE
REINFORCMENT, OVER
DRIVING & POOR DOLLY.
ACCURATE
ACCURATE
N.A
CAN OCCUR.BUT CAN BE

MINIMISED OR AVOIDED
IF MINIMUM M30
CONCRETE MIX AND MIN
2% STEEL
REINFORCMENT USED.
DOES NOT OCCUR.
COST-TIME LOGISTICS & OTHER ASPECTS

1
2
MOBILISATION
OPERATOR SKILLS
1 MONTH
EXPERIENCED
OPERATOR &
CLOSE
SUPERVISION
1 MONTH
EXPERIENCED OPERATOR
& CLOSE SUPERVISION
1 MONTH
PARTICULAR SKILLS NOT
NECESSARY.
CONSTRUCTION METHOD
& SPEED
RATHER SLOW
MEDIUM SPEED
FASTEST
LENGTH OF PILE
MOST FLEXIBLE
FLEXIBLE
FLEXIBLE
123
SL.No.
FACTOR
BORED CAST
INSITU
DRIVEN CAST IN SITU
DRIVEN PRECAST
GESTATION TIME
7 DAYS FOR EACH

PILE
28 DAYS FOR FIRST

CASTING FIRST SET UP
OF PILES IN YARD AFTER
MOBILISATION.
A
B
SITE CONGESTION
GROUND CONDITION
FLEXIBLE
DRY & LEVEL GROUND
ESSENTIAL
ENVIRONMENTAL
CLEAN
CLEAN
NOISE LEVEL
NOT LIKELY
PREFERABLY DRY
& LEVEL ABOVE
WATER TABLE
MESSY DUE TO
BENTONITE
LOW
7 DAYS FOR EACH PILE

ADDITIONAL
PRECAUTION
NECESSARY.DUE TO SOIL
DIFFERENCE HEAVE
WHILE DRIVING
ADJACENT.
FLEXIBLE
DRY & LEVEL GROUND
DESIRABLE
HIGH
(EAR PLUGS/EAR MUFFS
IS MUST)
CAN OCCUR BUT CAN BE
REMIDED BY REDRIVING.
PILE CONSTRUCTION &

SUB SURFACE
INTERACTION GROUND
HEAVE
RESTRICTION ON PILE
SIZES
CROSS SECTION
HIGH
(EAR PLUGS/EAR MUFFS
IS MUST)
CAN OCCUR
DIFFICULT TO DRIVE
LARGE DIA > 600 MM
DIA
DIFFICULT TO HANDLE >

600MM DIA.
LENGTH
DIFFICULT FOR VERY

LONG LENGTH
GENERALLY LIMITED TO
20-22 M.GREATER
LENGTH CAN BE
ACHIEVED BY JOINED
SECTION.
COSTLIER THAN BCIS

NORMAL
SIMPLE/
SOPHISTICATED
COSTLIEST
NORMAL
SIMPLE/
SOPHISTICATED
DOES NOT OCCUR
ONLY CIRCULAR.
DIFFICULT TO
CONCRETE LESS
THAN 400 MM DIA
ANY LENGTH
COMMERCIAL CONSIDERATIONS
1
2
3
TOTAL COST
LEAST
INFRASTRUCTURES AT SITE NORMAL
EQUIPMENT
SIMPLE/
SOPHISTICATED
124
List of reference codes

I S 2911 part -1 (sec 1) - Design & construction of pile foundation
(DCIS)
I S 2911 part -1 (sec 2) - Design & construction of pile foundation
(BCIS)
I S 2911 part -1 (sec 3) - design & construction of pile foundation
(Driven precast))
IS 2911 part-4 Load test on piles.
I S 14593 Design & construction of bored cast-in-situ piles founded
on rocks.
IS 14893 Non destructive integrity testing of piles
BS-8004 1996 code of practice for foundations
A
STM d 5882 -07 standard test method for low strain impact integrity
testing of deep foundations
A
STM d 4945 00 - standard test method for high-strain dynamic
testing of piles.
125
INSTALLATION SEQUENCES - DRIVEN CAST-IN-SITU PILES.
126
INSTALLATION SEQUENCES - BORED CAST-IN-SITU PILES
127
CONCRETING OPERATION IN A BCIS PILE.
128
Characteristics of bentonite suspensions for Bored Cast in Situ Piles:
129
IMPORTANT THINGS TO BE FOLLOWED

DRIVEN CAST-IN-SITU PILES
Plan movement of rig with respect to group of piles, Based on Priority of
the Structure.
Cross check the location of piles with reference points.(Survey)
heck the pile shoe for stiffener welding. Ensure full welding is done
C
instead of tack weld.
lace the pile shoe in the survey locations by excavating 200mm soil and
P
place sand bags above the pile shoe after checking the Point.
pply Bitumen in the annular space between the casing and pile shoe to
A
avoid water ingress.
heck for verticality of casing during driving and Monitor frequently &
C
Record.
Maintain Height of Fall as per set Calculation .Record the No.of blows
and record as per the Format.
Terminate the pile based on set criteria.
heck for water ingress inside the casing before concreting using water
C
level indicator(make AIMIL)
Check for proper welding of rebar lap joints.
Maintain proper cover.
L ower the Reinforcement carefully and hold the reinforcement and monitor
the same during Extraction.
Keep the concrete slump between 100mm to 150 mm.
roper care during withdrawal of casing. (The energy required for
P
withdrawal should be half of driving. This will ensure proper compaction
of concrete inside.)
he concrete pressure > overburden pressure always during extraction of
T
casing.
Check for Theoretical Vs Actual concrete consumption for each pile.
Check the Top of concrete after extraction from NGL
130
aintain a gap of 6d between construction of successive piles.(where d

M
= diameter of pile )
Piling sequence is to be followed.
ile Driving shall normally be from the center to periphery or from one
P
side to other of a pile group.
ackfill the Empty bore (unconcreted portion above COL) of the pile with
B
sand or with approved materials.
BORED CAST IN-SITU PILES
Fix the pile point &Cross check the location of piles with reference
points.
Drive the Temporary casing vertically in Location.
ill the Bentonite slurry inside the bore. Always maintain the head of
F
Bentonite slurry 2M above Water table.
Check for verticality during drilling continuously and Record.
Collect the soil sample from the bore and record.
Check for bentonite slurry quality regularlyby testing the same for
flow, specific gravity and density during drilling and after flushing and
record.
Check the length of drilling by sounding using chain links.
erminate the pile as per Drawing. If specified by client, terminate the pile
T
based on SPT.
If socketing in Rock, Terminate the same as per Drawing.
Clean the bore thoroughly before inserting Reinforcement.
I nsert reinforcementcage. If length of pile is more, ensure proper splice
welding is done on reinforcement cage while insertion.
Check for Tremie pipes cleanliness & threading arrangement before
concreting.
L ower the Tremie and continue flushing with fresh bentonitetill we get
bentonite slurry specific gravity equivalent to fresh slurry.
131
I nsert Tremie pipe to the required length leaving a gap of 100mm from
pile toe level and Record.
remie pipe diameter should be >200 mm for concrete mix having 20mm
T
size aggregates.
Check the Capacity of Concrete Hopper.
tart concrete operation after flushing and after checking the specific
S
gravity of slurry.
eep the concrete slump between 150mm and 180 mm. Grade of
K
concrete as per approved Mix Design.
remie pipe should be always 2 to 3 m inside the concrete during concreting
T
operation
hile removal of Tremie shake the same to ensure proper compaction
W
of concrete , ensuring that the Tremie pipe does not leave the concrete
surface
Maintain the Record of Tremie Removal during operation.
he concrete pressure > overburden pressure always during concreting
T
with Tremie.
All concrete operation should be completed within six hours.
ackfill the Empty bore if any(unconcreted top portion, i.e., from COLto
B
EGL) of the pile with sand or with approved materials.
Muck shall be disposed at designated area/dump yard.
DRIVEN PRECAST PILES
Prepare a neat leveled casting bed free from undulations.
Check the alignment during and after casting the piles.
The pile shoe should be properly aligned during casting.
Lifting hooks should be properly positioned.
nsure concrete has flown inside and well compacted near pile shoe and
E
end points.
se Concrete(grade as specified in GFC drawing) with a slump of 80 to
U
130mm for casting
132
heck whether the precast piles have attained the required strength before
C
lifting it.
Lift the pile with Lifting arrangements (Strand back)
Cross check the location of piles with reference points.
Check for verticality during driving.
Take extra precaution for splice joints.
ile driving sequence should be properly followed. Pile driving shall be
P
from Centre towards outside or from one end to other end in a pile
group.
Use stress band at the top of the pile during pile driving.
If the precast pile length exceeds 22m length, then joints are required
PRECAST PILES JOINTS:
MALE JOINT
FEMALE JOINT
133
LOAD TEST ON PILES

Vertical Load Test:
Intial Load Test
Routine Load Test
Test load = 2.5 times of design load Test load = 1.5 times of design load
or upto failure whichever is earlier.
or 12mm whichever is earlier
Load test will be carried on Initial Load test will be conducted on
test piles seperately casted especially working piles. The quantity will be
during beginning of project.
generally 1.5% to 2% of total number
of piles.
Type of Arrangements:
entledge Method (Placing of Concrete blocks or Sandbags over
K
platform)
Anchor Method
By Rock anchors.
By Anchor piles.
134
VERTICAL LOAD TEST ARRANGEMENTS:
135
Arrangement for Vertical Load Test
136
Vertical Load Test Photograph

LATERAL LOAD TESTS ARRANGEMENTS:
137
PULLOUT (OR) UPLIFT TEST ARRANGEMENTS:
Lateral Load Test Photograph
PULLOUT (OR) UPLIFT TEST ARRANGEMENTS:
138
Pull Out Test Photograph
139
PILE INTEGRITY TEST:

This test evaluates the pile integrity and pile physical dimensions (that is,
cross-sectional area, length), continuity, and consistency of the pile material,
although evaluation is approximate and not exact. This test method will not
give information regarding the pile bearing capacity.
Good Pile
Defective Pile
PDA TEST (HIGH STRAIN DYNAMIC TEST):

This test method is used to provide data on strain or force and acceleration,
velocity or displacement of a pile under impact force. The data are used to
estimate the bearing capacity and the integrity of the pile, as well as hammer
performance, pile stresses, and soil dynamics characteristics, such as soil
damping coefficients and quake values.
140
PDA test (High strain Dynamic test)
141
O-CELL TEST :
142
143
O-CELL TEST ARRANGEMENT:
144
1.
Cement
Cement and Mineral

Admixtures
Types of cement available:

As per IS 456-2000 the cement used shall be any of the following and the
type selected should be appropriate for the intended use:
a)
33 Grade ordinary Portland cement confirming to IS 269
b)
c)
d)
Rapid hardening Portland cement confirming to IS 8041
e)

Portland slag cement confirming to IS 455 ( with slag content 35 % to

70 %)
f)

Portland pozzolana cement (fly ash based) confirming to IS 1489

(part 1)(with fly ash content 15% to 35%)
g)

Portland pozzolana cement (calcined clay based) confirming IS 1489

(part 2)
h)
Hydrophobic cement confirming to IS 8043
i)
Low heat Portland cement confirming to IS 12600
j)
Sulphate resisting Portland cement confirming to IS 12330.
Other combinations of Portland cement with mineral admixtures like Fly ash,
Silica fume, Rice husk ash, Metakaoline and GGBFS of quality confirming
with relevant Indian standards may also be used in the manufacture of
concrete provided that there are satisfactory data on their suitability, such as
performance test on concrete containing them.
Low heat Portland cement confirming to IS 12600 shall be used with adequate
precautions with regard to removal of formwork, etc, Highalumina cement
confirming to IS 6452 and Supersulphated cement confirming to IS 6909
may be used under special circumstances with prior approval of Engineer-incharge. Specialist literature may be consulted for guidance regarding the use
of these types of cements.
145
Test Certificates : Sampling requirements.

a)

When the cement has ISI Certification mark, or when it comes with
manufactures certificate, no further testing is usually required.
b)

If clients still insist, one sample for every 250 tonnes or batch of cement
may be tested for physical properties or sent for testing to an external
agency.
c)

Take the samples within one week from receipt of cement and arrange
to test within one week from the date of sampling.
d)

Send the sample for testing atleast 10 days before the cement is to be
used.
e)

A sample should consist of twelve roughly equal portions, each portion

taken from different bag. The total weight of the sample should be 4 to
5 kg.
Problems of setting and hardening .

a)
False set : Concrete may stiffen too early say with 5 to 20 minutes
after mixing. This problem arises because of inadequate cooling during
grinding of cement or because cement is fresh and hot from the mill. If
false set occurs remix the concrete without adding water. Plasticity will
return and concrete will set in the normal manner. ( IS 4031 part 14
Method of test for determination of false set.)
b)

Flash set : If concrete stiffens too early and does not regain plasticity on
re-mixing, flash set might have occurred. The cause may be ,
1)
Use of hot water ( 60o C to 80o C) for mixing.
2)
Presence of calcium chloride, especially in admixture.
3)

Contamination with high alumina cement or calcium chloride , possibly

stored for emergency repairs.
c)
Pozzolana and Slag cement :
Concrete with pozzolana cement and slag cement hardens at slower rate.
Therefore, prolonged curing is necessary.
146
Simple Physical tests and Interpretations.

a)
Fineness : IS 4031 Part 1 Determination of fineness by dry sieving.
Sieve about 100 g of cement on a 90 micron sieve. The amount retained

should be not more than five percent by weight for Rapid hardening cement
and ten percent by weight for other cement types. Usually this requirement is
met. If not a better test using Blaines apparatus will be necessary to find out
specific surface in m2 / kg
b) Standard consistency : IS 4031 part 4 Determination of standard
consistency of cement paste.
The standard consistency of the cement paste is as that consistency which
will not permit the vicat plunger to penetrate to a point 5 to 7 mm from bottom
of mould. In general the consistency ranges between 26 % to 34 %. No
limitations as per IS .
c)
Setting Time : IS 4031 part5 Determination of setting time of cement
The cement paste made with 85 % of standard consistency water, the initial
setting time should not be less than 30 minutes and final setting time should
not be more than 10 hours. However the limits of setting time for different
types of cement should confirm to the respective Indian standards.
d) Loss on Ignition : IS 4032 Method of Chemical Analysis of Hydraulic
cement
This shows the amount of moisture and carbon dioxide absorbed by the cement.
If cement is stored for a longer time (say three months) or if deterioration is
suspected, check the cement for loss on ignition. This test can be done in an
outside laboratory. The value should not be more than four or five percent by
weight of cement.
e) Insoluble Residue : IS 4032 Method of Chemical Analysis of Hydraulic
cement
Insoluble residue is found by dissolving cement in hydrochloric acid. For
ordinary PortlandCement this should not be more than 2 to 4 % by weight of
cement. For pozzolana cement this may amount to 15% to 20 %
f) Test for Soundness: IS 4031 part 3 Determination of soundness for
hydraulic cement.
147
Le Chatelier test reveals the soundness caused by excess amount of

uncombined(free) lime. Autoclave tests reveal the soundness caused by
excess amount of percales crystals(MgO)It is not necessary to perform tests
for soundness at site.
g) Compressive strength of Mortar cubes: IS 4031 part 6 Determinationof
compressive strength of Hydraulic cement other than masonry cement.This is the average compressive strength of three mortar cubes of size 70.7
x 70.7 x 70.7 mm prepared using one part of cement with three parts of
standard sand confirming to IS 650 with( P/4+ 3 .0) percent (of combined
mass of cement and sand) water.
Where P = Standard consistency of the cement in % ,
Supplementary Notes
a.
ISI certification , week and year of manufacture are printed on the bag
b.
Bags containing Ordinary Portland cement, Portland pozzolana cement

and railway sleeper cements are marked respectively with black, red and
green colour prints. Other cement bags are printed with black colour.
c.
Percentage of slag in slag cement for pre-stressing concrete works should

not exceed 50 %.
d.
Do not use high alumina cement for structural use.
e.
Concrete mix containing hydrophobic cement should be mixed for a

longer time than usual.
f.
Portland Pozzolona manufactured by blending or inter-grinding flyash in

the range of 15% to 35% maximum
g.
Portland slag cement manufactured by inter-grinding slag granules in

the range of 25% to 70% maximum.
h.
Sulphate resistant cement has C3A content of 5 % max.
148
Physical requirements of cement
OPC
OPC
33
43
Grade Grade
OPC
53
Grade
269
8112
12269 12330
1489
part 1
455
Fineness (Blaine)
2250
(sq. cm / gm ) Min
2250
2250
2250
3000
2250 3700
Setting Time (Minute)

Initial (Not less than) 30
Final ( Not more
600
than)
30
600
30
600
30
600
30
600
30
600
60
600
Soundness
10
1)Le Chatelier (mm)
10
10
10
10
10
2) Autoclave (%)
0.8
0.8
0.8
0.8
0.8
0.8
0.8
160
230
270
100
160
160
7 Days
220
330
370
160
220
220
375
28 Days
330
430
530
330
330
330
0.15
Type of cement
IS Code No
Compressive
strength (Kg/
Sq.cm) Min
3 Days
Drying shrinkage
(max %)
149
SRC
PPC
(Flyash
Based)
PSC
Sleeper
53 S
12269
Mineral admixtures:
IS 456-2000 permits the usage of the following pozzolanic materials confirming
the relevant standard specification can be used in concrete as admixtures with
the permission of the deciding authorities.
Fly ash (pulverized fuel ash ) confirming IS 3812-1981
Ground granulated blast furnace slag (GGBFS) confirming IS 12089 &
BS 6699
Silica fume confirming IS 15388
Rice husk ash
Metakaoline having fineness between 700 to 900 m2/kg. confirming IS
In general fly ash , GGBFS and in some cases Silica fume is used depends on
project requirement. But fly ash is used in major quantity in concrete making
as part replacement to cement.
FLY ASH:
Fly ash is the by product of coal fired power plants. The ash which is very small
in size is collected by the ESPs. The chemical composition mainly depends up
on the type of coal used for firing in the boilers.
The details of requirement of Chemical and Physical properties of Fly ash for
use as a pozzolana for part eplacement of cement , for use as an admixture
is given below.
Grade designation : As per IS 3812- Part 1 - 2003 fly ash is designated as
Siliceous Pulverized Fuel Ash Pulverized fuel ash with reactive calcium
oxide less than 10 percent,by mass. Such fly ash are normally produced from
burning anthracite or bituminous coal and has pozzolanic properties.
Calcareous Pulverized Fuel Ash Pulverized fuel ash with reactive calcium
oxide not less than 10 percent by mass. Such fly ash are normally produced
from lignite or sub-bituminous coal and have both pozzolanic and hydraulic
properties
150
Chemical requirements
When tested according to IS 1727-1967 fly ash to confirm the following
requirements.
Chemical requirements of fly ash
Sl.
No
Characteristic
Siliceous
Calcareous
Silicon dioxide(SiO2) plus aluminium

oxide (Al2O3) plus iron oxide
(Fe2O3) percent by mass ( Min)
70.0
50
Silicon dioxide (SiO2) percent by

mass (Min)
35.0
25
Reactive Silica in percent by mass,

Min *
20
20
Magnesium oxide (MgO) percent by

mass ( Max)
5.0
5.0
Total sulphur as sulphur trioxide

(SO3), percent by mass (Max)
3.0
3.0
Available alkalis as sodium oxide

(Na2O) , percent by mass (Max)
1.5
1.5
Total chlorides in percent by mass,

Max **
0.05
0.05
Loss on ignition, percent by mass

(Max)
5.0
5.0
Requirements
* Optional Test
** For the purpose of this test, wherever reference to cement has been made,
it may be read as pulverized fuel ash.
151
Physical requirements of fly ash (tested as per IS 1727-1967)

Sl. No.
Characteristic
Requirements
Fineness- specific surface in m2 / kg by

Blaine Air permeability method (Min)
320
Particles retained on 45 microns IS sieve

(wet sieving) percent Max
34
Lime reactivity average compressive

strength N/mm2 (Min)
4.5
Not less than 80

Compressive strength at 28 days in N/ percent of the strength
of corresponding plain
mm2 (Min)
cement mortar cubes
Soundness by autoclave test expansion

of specimens, Percent (Max)
0.8
Not withstanding to the strength requirements specified above the fly ash
incorporated shall show a progressive increase in strength.
In case of fly ash is used as replacement to cement a maximum of 35 % is
permitted. But field trials to be conducted to estimate the strength development
before the concrete mix is used. An optimum dosage of 20% to 25 % is found
to give satisfactory results.
Note : Fly ash in general classified as Calcareous ( class C) & Siliceous
(Class F). Fly ash of Class C is obtained from power plant where Lignite
is used as fuel and Class F obtained from power plants where bituminous
coal is used as fuel. In general in India , majority availability is fly ash of
Class F .
Advantages of using fly ash in concrete
In plastic state concrete:
1)
Improved workability: Fly ash is spherical in shape it produces a paste

with superior plasticity and reduces the amount of water needed in a
mix.
152
2)
Reduced Segregation: The improved cohesiveness of Fly ash concrete

provides added body to plastic state concrete which resist segregation.
3)
Reduces Bleed water: The lower water content required for workability in
fly ash concrete reduces bleeding.
4)
Increased pumpability : The spherical shape of fly ash acts like a tiny
ball bearing, reducing internal friction, thereby producing a mix that is
easier to pump.
5)
Reduces Equipment wear: Fly ash concrete reduces wear on delivery

and plant equipment because of the reduction of friction attributed to
the spherical nature fly ash.
Long Term advantages of fly ash :

1)
Increases concrete strengths: Fly ash concrete will continue to gain

strength past the age of 28 days. With improved workability and a
reduction in water needed , fly ash concrete provides a lower water /
cementitous ratio there by producing superior strengths and longer life.
2)
Reduces drying shrinkage: By providing as much as 10 % water reduction

in its plastic state, fly ash concrete maintains workability and reduces
drying shrinkage.
3)
Reduced permeability: The packing effect of the spherical fly ash particles
helps to reduce permeability. The chemical reaction between fly ash and
lime forms additional (C-S-H) bonds that block bleed channels and fill
pore space.
4)
Resistance to Sulphate attack: Fly ash combines with free calcium

hydroxide making it unavailable to react with sulphates. In producing
a less permeable structure there is increased resistance to aggressive
soluble sulphate solutions resulting in longer life.
5)
Mitigates alkali aggregate: Fly ash reacts with available alkalis in

the hardened cement matrix making them less likely to react with the
aggregate.
6)
Reduces heat of hydration: Large masses of concrete typically produce

high internal temperature and thermal cracking. Fly ash concrete
produces appreciably less heat than portland cement concrete.
153
GGBFS: (Ground Granulated Blast Furnace Slag)

Granulated slag is a non-metallic product consisting essentially of glass
containing silicates and aluminizes of lime and other bases. It is a product
developed simultaneously with iron in blastfurnace of pig iron furnace.
Granulated slag is obtained by further processing the molten slag by rapidly
chilling or quenching it with water or steam and air. Ground granulated blast
furnace slag confirming IS 12089 Chemical retirements can be used as an
mineral admixture as part replacement to cement .
No IS code reference available for GGBFS as IS 12089 refers to granules of
slag. BS 6609 has references to slag and in India GGBFS produced satisfy
the requirement of BS 6609.
IS 456 stipulates GGBFS can be used as part replacement of cement in concrete
mixes and the range of addition is as stipulated in IS 455. A minimum of 25%
and a Maximum of 70 % can be used as part replacement of cement, but an
optimum dose of 50% replacement gives maximum benefits to concrete.
Micro silica & Metakaolin
Microsilica and Metakaolin are used in high strength concrete as cementitious
material. An optimum addition of 5% to 8 % by weight of cementtious material
will produce more durable concrete.
In general addition of these material in concrete will result in
Increased durability
Greater resistance to chemicals
High strength
High resistance to chlorides and sulfates
Protection against corrosion
Silica fume addition usually increases water demand. If it is desired to
maintain the same water-to-cementitious materials ratio (by mass), waterreducing admixtures or HRWRA or both should be used to obtain the required
workability. In order to maintain the same apparent degree of workability, a
somewhat higher slump will normally be required for silica fume concrete
because of the increased cohesion.
154
Aggregates:
Aggregates in general are inert material and occupy nearly more than 75
percent of concrete volume. The quality of aggregate is more important since
it is concerned with the durability of concrete. Aggregates in general are
classified into three types as coarse aggregate, fine aggregate and all-inaggregate. Aggregates used in concrete should satisfy the requirement of IS
383 Specification for Coarse and Fine aggregates from natural sources for
concrete.
1.
Fine aggregate: Aggregates most of which passes 4.75 mm IS sieve and

contain only so much percentage of material passing in 600 micron IS
sieve as specified for the relevant Zones, and classified as Zone I , Zone
II, Zone III and Zone IV.
The following are the types of fine aggregates in general used for production
of concrete
2.
1.
Natural Sand : Fine aggregate resulting from the natural

disintegration of rock and which has been deposited by streams or
glacial agencies.
2.
Crushed Stone Sand : Fine aggregates produced by crushing hard

stone.
3.
Crushed Gravel Sand:

natural gravel.
Fine aggregate produced by crushing
Coarse aggregate: Aggregates most of which is retained in 4.75 mm

IS sieve and containing only so much finer material as permitted for the
various types specified in the standard.
Coarse aggregates may be described as:
a)
Uncrushed gravel or stone which results from natural disintegration

of rock.
b)
Crushed gravel or stone when it results from crushing of gravel or

hard stone.
c)
Partially crushed gravel or stone when it is a product of the blending

of a) & b).
155
3.
All-in-aggregate : Material composed of fine and coarse aggregates.

Based on the particle shape aggregates are further classified in to the
following types.
1.
Rounded : Fully water worn or completely shaped by attrition (e.g.

River or seashore gravel, desert, seashore and windblown sands.
2.
Irregular or partly rounded : Naturally irregular , or partly shaped

by attrition and having rounded edges. ( e.g. Pit sands and gravel,
land or dug flints , cuboid rock)
3.
Angular : Possessing well-defined edges formed at the inter-section

of roughly Planar faces. (e.g. Crushed rocks of all types, talus,
screes)
4.
Flaky : Material usually angular, of which the thickness is small

relative to the width and / or length ( e.g. Laminated rocks)
Data for storage planning :

a)
For calculating the volume of heap of aggregate or sand, assume

a natural slope of 1.25 horizontal to 1.00 vertical.
b)
For rough calculation assume 0.625 cu.m. per tonne of aggregate

or 1.60 tonnes of aggregates per cu.m.
c)
A conical heap of aggregate having base diameter D (meters)

contains D3 / 6 tonnes of aggregates.
d)
A long non-retained bank of aggregate, L meter wide at base

contains L2/3 tonnes of aggregates per meter.
e) Make appropriate allowance if aggregate is retained against

vertical surfaces.
Storage and Handling of aggregate
As per IS 4082 Aggregates shall be stored at site on a hard dry and level
patch of ground. If such a surface is not available , a platform of planks or
old corrugated iron sheets, or a floor of bricks, or a thin layer of lean concrete
shall be made so as to prevent contamination with clay, dust, vegetation and
other foreign matter.
156
a)
Store sand and coarse aggregates of different size fractions in separate

stock piles, on firm ground or platform.
b)
If aggregates are stored directly over firm ground, do not use the material
in the bottom 10 cm portion( This will be a Dead storage)
c)
Provide ample space between adjacent stock piles ( about one meter).
d)
Build up the stock pile in horizontal or gently sloping layers. Do not

allow dumping of aggregates down the sloping sides of big stock piles.
e)
Do not allow wheel loaders, trucks and bull dozers over the stock piles.
f)
Maintain the amount of under sized fraction in each aggregate with in

the limit specified in IS 383.
g)
Do not blend two sizes of sand by placing them alternatively in stock

piles or trucks. Always maintain additional stock piles and batch them
separately in to the mixer.
h)
If the aggregates have been washed or received wet, allow atleast 48

hours for the excess water to drain away
i)
As far as possible avoid screening and washing of aggregates at the

concreting site. The same should be done at the source or crusher if
required.
j)
Aggregates may be covered with low roofed sheds if concreting is done

at temperatures above 40o C
Selection of size of aggregate for concrete :

The nominal maximum size of coarse aggregate should be as large as
possible within the limits specified but in not case greater than one-fourth
of the maximum thickness of the member, provided that the concrete can be
placed without difficulty so as to surround all reinforcement thoroughly and
fill the corners of the form. For most work, 20 mm aggregate is suitable.
Where there is no restriction to the flow of concrete into sections, 40 mm or
larger size may be permitted. In concrete elements with thin sections , closely
spaced reinforcement or small cover, consideration should be given to the use
of 10mm nominal maximum size.
157
Plums above 160 mm and up to any reasonable size may be used in plain
concrete work up to a maximum limit of 20 percent by volume of concrete
when specifically permitted. The plums shall be distributed evenly and shall be
not closer than 150mm from the surface.
For heavily reinforced concrete members as in the case of ribs of main beams,
the nominal maximum size of the aggregate should usually be restricted to
5 mm less than the minimum clear distance between the main bars or 5 mm
less than the minimum cover to the reinforcement which ever is less.
The aggregate used should satisfy the following requirements given in IS
383
Limits of the content of Deleterious Materials (IS 383)
Percentage by weight of aggregate
Deleterious
substance
Fine aggregates
Coarse aggregates
Uncrushed
Crushed
Uncrushed
Crushed
Coal and lignite
1.00
1.00
1.00
1.00
Clay lumps
1.00
1.00
1.00
1.00
3.00
Material finer than 75

micron IS sieve
3.00
15.00
3.00
3.00
Shale
1.00
Total percentage of all

deleterious materials *
5.00
2.00
5.00
5.00
Soft fragments
* Excluding Mica
Mechanical properties
Test
Wearing surface
Non Wearing Surface
Impact Value
30% Max
45 % Max
Crushing Value
30% Max
45 % Max
Abrasion Value
30% Max
50 % Max
158
Grading requirement of Single size coarse aggregate (IS 383)

Cumulative percentage passing I S Sieves for coarse aggregates
IS Sieve of nominal size
63 mm
40 mm
25 mm
20 mm
16 mm
12.5 mm
10 mm
80 mm
100
63 mm
85100
100
40 mm
0 30
85100
100
25 mm
85100
100
20 mm
05
020
85100
100
16 mm
85100
100
12.5 mm
0 20
85100
100
10 mm
0 5
0 5
020
0-30
045
85100
4.75 mm
05
05
0-5
0 10
0 20
2.36 mm
05
Grading requirement of Graded coarse aggregates ( I S 383)

I S Sieve
Cumulative percentage passing IS Sieves for coarse aggregate

of nominal size
40 mm
25 mm
20 mm
16 mm
12.5 mm
80 mm
100
40 mm
95 100
100
100
25 mm
90 100
20 mm
30 70
95 100
100
100
16 mm
90 - 100
12.5 mm
25- 55
25 -55
90 100
10 35
30 70
40 85
0 5
05
05
0 - 10
0 10
10 mm
4.75 mm
159
Grading requirement of sand ( IS 383)

I S Sieve
Cumulative percentage passing I S sieves for grading zone

I
II
III
IV
100
100
100
100
4.75 mm
90 100
90 100
90 100
95 100
2.36 mm
60 95
75 - 100
85 - 100
95 100
1.18 mm
30 70
55 - 90
75 - 100
90 - 100
600 micron
15 - 34
35 - 59
60 - 79
80 - 100
300 micron
5 - 20
8 - 30
12 - 40
15 - 50
150 micron
0 - 10
0 - 10
0 - 10
0 - 15
75 micron
0 - 3
0 - 3
0 - 3
0 - 3
10 mm
Note : If the grading falls outside the limits of any particular sieve other than 600 micron IS
sieve by a total amount of 5 percent it shall be regarded falling within the zone. This limit is not
applicable for coarser limits of zone I and finer limits of zone IV. For crushed sand 150 microns
parsing increased to 20 percent.
Grading limits for crushed sand used as fine aggregate

Cumulative percentage passing IS sieve
I S Sieve
10 mm
Crushed Sand
Crushed sand + Natural

sand
100
100
4.75 mm
90 100
90 100
2.36 mm
75 100
75 100
1.18 mm
55 100
55 100
600 micron
30 70
30 70
300 micron
8 40
8 40
150 micron
0 20
0 15
75 micron
0 - 15
09
160
All-in aggregate grading
IS Sieve
Cumulative percentage passing IS sieve

40 mm
25 mm
20 mm
12.5 mm
80 mm
100
40 mm
95 100
100
100
95 100
95 100
100
95 100
25 mm
20 mm
45 75
12.5 mm
4.75 mm
25 45
30 50
30 50
35 55
600 micron
8 30
10 35
10 35
12 40
150 micron
06
0 10
0 - 10
0 12
1.
The relaxed limits for crushed sand are applicable only if the boulders
used for crushing in the crusher are free from natural over burden soil /
muck.
2.
The following Table13 is the guidance for selecting the percentage 4.75
mm passing in all-in-aggregate grading precisely.
Mixing Water
a)
Potable water is satisfactory for mixing concrete.
b)
Water should be free from oils, acids, alkalis, salts, sugar and organic
materials.
c)
In general , do not use sea water either for mixing or for curing . However
IS 456-2000 permits use of sea water for Plain concrete and reinforced
concrete permanently immersed in sea water.
d)
The total requirement of water, for all purposes such as mixing, curing,
washing of shutters, washing of aggregates and workmens consumption
may be estimated on the basis of 370 to 500 litres / m3 of concrete.
As a guide the following concentrations represent the maximum

permissible values:
161
a)
To neutralize 100 ml sample of water, using phenolphthalein as an

indicator, it should not require more than 5 ml of 0.02 normal NaOH.
b)
To neutralize 100 ml sample of water , using mixed indicator, it should

not require more than 25 ml of 0.02 normal H2SO4
c)
pH value of water shall not be less than 6.
IS 456 2000 stipulates the permissible limits of solids shall be as follows

Sl.No
Permissible Solids
Permissible Limit (Max)
Organic
200 mg/l
Inorganic
3000 mg/l
Sulphates (as SO3)
400 mg/l
Chlorides (as Cl)
2000 mg/l for PCC and

500 mg /l for RCC
Suspended matter
2000 mg /l
In case of doubt regarding the usage of water the same can be tested for
setting time and compressive strength test as mentioned below.
1)
The average 28 days compressive strength of at least three 150 mm

concrete cube prepared with water proposed to be used shall not be
less than 90 percent of the average of strength of three similar concrete
cubes prepared with distilled water.
2)
The initial setting time of test block made with the appropriate cement
and the water proposed to be used shall not be less than 30 min and
shall not differ by 30 min from the initial setting time of control test
block prepared with the same cement and distilled water.
Admixture
Admixtures are the fourth ingredients in concrete making, which are added
to cement, aggregate and mixing water. Admixtures are added to concrete
mix immediately before or during its mixing , to modify one or more of the
properties of concrete in the plastic and hardened states. Admixtures used in
concrete should satisfy the requirement of IS 9103.
162
Admixtures are of four types:

1.
Accelerating admixtures
2.
Retarding admixtures
3.
Water reducing admixture and
4.
Air entraining admixtures
Before using an admixture in concrete, the performance of it should be evaluted

by comparing the properties of concrete with and without any admixture.
Though the admixtures are intended to modify a single property of concrete,
some admixtures available are capable of modifying more than one property
of concrete.
Eg. Water reducing admixtures can also be set retarders.
In addition , an admixture can improve the desirable properties of concrete
in more than one way. For example , water reducing admixtures can be
used : (a) to increase the workability of concrete with the same water and
cement contents, (b) to increase the compressive strength of concrete without
changing the workability by reduction of the water content in the concrete
mix, when the cement content is unaltered, or to effect saving in cement by
reduction in both the cement and water contents in the mix, while maintaining
the same workability and compressive strength as in the reference concrete.
Every batch of admixture to be tested for compatibility before use. The
concrete mix design carried out with the admixture shall be rechecked for
increase in slump, slump retention, setting time and strength development.
The performance should not defer from initial sample and trial conducted
during trial stage.
Concrete
The concrete mix should be proportioned in such a way , it should give a
uniform colour, easily transported, handled and placed in its final position with
out difficulty and has given the required shape of the member as designed.
According to IS 456-2000 clause 9.2.1, As the guarantor of quality of concrete
used in the construction, the constructor shall carryout the mix design and mix
163
so designed (not the method of design) shall be approved by the employer

within the limitations of parameters and other stipulations laid down by the
standard IS 456-2000.
Concrete mix design for the grades of concrete used in project site can be
designed by considering the durability, Workability, Minimum cement content,
maximum water cement ratio, maximum size of aggregate and cement type
to used, method of placement, reinforcement congestion etc. Mix designed
asper10262, ACI or any other accepted method and mixes so designed
should satisfy the parameters laid down by IS 456.
Grades of concrete (IS 456-2000)
Group
Grade Designation
Specified characteristic compressive

(1)
Ordinary Concrete

Strength of150 mm
28 days in N/mm2
(2)
M 10
cube
at
(3)
10
M 15
15
M 20
20
Standard concrete
M 25
25
M 30
30
M 35
35
M 40
M 45
40
45
M 50
50
M 55
55
High strength concrete M 60
60
M 65
65
M 70
70
M 75
75
M 80
80
164
Note :
1.
In the designation of concrete mix M refers to the mix and number to

the specified compressive strength of 150 mm size cube at 28 days
expressed in N/mm2
2.
For concrete of compressive strength greater than M 55 design

parameters given in the standard may not be applicable and the values
may be obtained from specialized literature and experimental results.
Exposure Conditions as Per is 456-2000

S.No
Environment Exposure condition
Mild
Concrete surface protected against weather or

aggressive conditions, except those situated in coastal
area
Moderate
Concrete surface sheltered from severe rain or freezing

whilst wet, concrete exposed to condensation and
rain , concrete continuously under water, concrete in
contact or buried under non aggressive soil/ground
water, concrete surfaces sheltered from saturated salt
air in coastal area
Severe
Concrete surfaces exposed to severe rain, alternate

wetting and drying or occasional freezing whilst wet or
sever condensation, Concrete completely immersed in
sea water, Concrete exposed to coastal environment
Very Severe
Concrete surface exposed to sea water spray, corrosive

fumes or severe freezing conditions whilst wet,
Concrete in contact with or buried under aggressive
sub soil/ ground water.
Extreme
Surface of members in tidal zone, Members in direct

contact with liquid / solid aggressive chemicals
Minimum cement content , Maximum water cement ratio and Minimum grade
of concrete for different exposure condition with normal weight aggregates of
20mm nominal size.
165
Plain concrete
Minimum
S.
No
Exposure
cement
content
(kg/cum)
Mild
Maximum Minimum
Reinforced concrete
Minimum
Maximum Minimum
free w/c
ratio
grade of
concrete
cement
content
(kg/cum)
220
0.60
300
0.55
M 20
Moderate 240
0.60
M 15
300
0.50
M 25
Severe
250
0.50
M 20
320
0.45
M 30
Very
Severe
260
0.45
M 20
340
0.45
M 35
Extreme
280
0.40
M 25
360
0.40
M 40
free w/c
ratio
grade of
concrete
Note:
1.
Cement content prescribed in this table is irrespective of the grade of

cement and inclusive of additions like fly ash and GGBFS and their
content also to be taken into account in the concrete composition with
respect to cement content and water cement ratio if the suitability is
established as long as the maximum amounts taken into account do not
exceed the limit of pozzolana and slag specified in IS 1489 Part I and IS
455 respectively.
2.
Minimum grade for plain concrete under mild exposure condition is not
specified
Requirement of concrete exposed to Sulphate attack
166
Concentration of
Expressed as SO3
Class
In soil
sulphates,
In
Ground
water
Total
SO3
SO3 in 2:1
water
:
soil
extract
Percent
g/l
g/l
Traces
(<0.2)
Less than
1.0
Less
than 0.3
to
1.0 to 1.9
0.3
1.2
Type of cement
Minimum
cement
content
to
Ordinary
portland
cement
or
Portland slag cement or portland
pozzolana cement
Ordinary
portland
cement
or
Portland slag cement or Portland
pozzolana cement
Supersulphated cement or Sulphate

resisting Portland cement
3
0.50 to
1.0
1.0
2.0
More
than
2.0
to
1.2
2.5
to
3.1 to 5.0
2.5
5.0
to
More than
5.0
More
than 5.0
1.9 to 3.1
Maximu
m free
w/c
ratio
(Kg/cum)
0.2
0.5
Dense
fully
compacted concrete
made with 20mm
Nominal
MSA
complying IS 383

Portland pozzolana
Portland slag cement
cement
or

Sulphate resisting Portland cement

or supersulphated cement with
protective coating
167
280
0.55
330
0.50
310
0.50
330
350
0.50
0.45
370
0.45
400
0.40
Notes:
Cement content given in this table is irrespective of grades of cement.
1.
Use of supersulphated cement is generally restricted where the prevailing

temperature is above 40OC
2.
Supersulphated cement gives an acceptable life provided that the

concrete is dense and prepared with a water cement ratio of 0.40 or
less , in mineral acids, down pH 3.5.
3.
The cement content given in col. 6 of this table is the minimum

recommended. For SO3 contents near the upper limits of any class
cement content above these minimum are advised.
4.
For severe conditions such as thin sections under hydrostatic pressure on

one side only and sections partly immersed, considerations should be
given to further reduction of water cement ratio.
5.
Portland slag cement confirming to IS 455 with slag content more than
50 percent exhibits better sulphate resisting properties.
6.
Where chloride is encountered along with sulphates in soil or ground

water ordinary Portland cement with C3A contents from 5 to 8 percent
shall be desirable to be used in concrete, instead of sulphate resisting
cement. Alternatively Portland slag cement confirming to IS 455 having
more than 50 % of slag or blend of ordinary Portland cement and slag
may be used provided sufficient information is available on performance
of such blended cement in these conditions.
Batching
Cement
a)
Cement should be batched in bags (50 kg each)
b)
Fractions of a bag of cement should always be weighed.
c)
Whenever a new consignment of cement is received check the weight of

several bags individually, for uniformity as well as for average weight.
d)
Check the number of bags emptied in to the batch, at frequent intervals.

Any irregularity in batching may also be detected from the appearance
of concrete.
168
e)
Keep a record of number of bags consumed. Received and in stock, The

stock should be checked regularly.
f)
The tolerance limit for batching of cement is 1 % by weight.
Aggregates
a)
If possible batch aggregates by weight.
b)
If the mix proportions, are given by weight (in case designed mixes) but
only volume batching could be done at site, then convert the weight to
volume by dividing the weights by loose bulk density.
Use only loose bulk density and not rodded bulk density for conversion. Loose
bulk density is determined by filling a known volume container loosely without
compacting and finding the weight and volume.
Weight of material loosely packed in the container
Loose bulk density =
----------------------------------------------------------
Volume of the container.
c)
Do not heap the sand or aggregates in the batch box. It should always
be struck level, so that constant volumes are measured out.
d)
Use separate batch boxes for different grades of concrete and different
aggregates. It is advisable to mark on the box with paint the grade
of concrete and type of aggregate, whether fine or coarse, over the
respective boxes for easy identification, Marking also helps in avoiding
use of wrong boxes.
e)
The size of batch boxes should be so arranged that aggregates can be

batched in whole number of boxes. When slight changes are required
(say for bulkage) nail marks maybe made on the boxes before batching
to show the height of filling in the boxes as required.
f)
In volume batching, when moist sand is used, allowance must be made

for bulking of sand, procedure for determining the bulking is given in
Appendix I.
g)
Batch tolerance for aggregates is 3 % by weight.

169
Water:
a)
Usually, water is measured by measuring cans or buckets in site mixers

and with water meter in batching plants.
b)
Batch tolerance for water is 3 % by weight as per IS 456
Procedure for Loading the skip

(a) When charging the skip or hopper with dry materials, first place the
coarse aggregate at the bottom followed by sand and cement.
(b) If the sand to be used is damp, first place half the coarse aggregate
in the skip, then the cement , followed by the fine aggregate and the
remainder of the coarse aggregate to prevent the mount of the skip
getting choked with the damp sand.
(c) Do not place materials in the skip unless they are to be mixed and used
immediately.
Checking batching devices/methods.
(a) See that batching hopper is empty and clean.
(b) See that hoppers, fulcrums, knife edges , and all moving parts are free
from binding, rubbing and friction. Knife edge bearing must be centered
and knife edges must be sharp.
(c) Balance scales on zero , dial scales should be checked atleast once daily
to ascertain that the hand returns to zero when batcher is emptied.
(d) In volume batching check if appropriate boxes are used for feeding the
aggregates. Also check if corrected quantity is being batched. Check if
correction for bulkage of moist sand is being done.
(e) Check for moisture content in sand and coarse aggregate daily. Do
necessary corrections before batching, if moisture is present.
Mixing time
In general the mixing time is 2 minutes. For automatic control plants the mixing
time can be as stated by manufacture. At the end of mixing time the concrete
from plant should have uniform colour, cohesive and free from segregation.
170
If mineral admixtures like microsilica, high volume fly ash , GGBFS used to
get uniform blending of the material the mixing time needs to be increased ,
normal experience shows it is 60 seconds to 90 seconds depend on quantity
of mineral admixture used.
In central control plant the mixing time for 0.5 cum batch should not be
less than 30 seconds. Refer to the cycle time diagram of the batching plant
manufacture for this.
Transporting concrete
(a) The method of conveying concrete should not cause segregation, loss of
part of the concrete and loss of slump.
(b) Do not add extra water to the concrete (in addition to what is required as
per the W/c ratio) for the purpose of easy handling / transporting.
(c) Properly designed and operated buckets are an excellent means of
transporting concrete. But they should be capable of discharging
low slump concrete and the discharge rate should be controllable.
Cylindrical buckets with proper center discharge gates are the most
efficient
(d) When using chutes for transporting , take care to avoid segregation.
The chutes should be of rounded cross-section and of smooth metal
to avoid sticking of concrete. They should be of correct slope so that
concrete of the required slump will slide without flowing. Usually,
the slope is 1 vertical to 2 or 2 horizontal but the best slope for a
particular concrete can be fixed after a few trials. Control should be
provided at the end of the chute so that concrete will drop vertically
without segregation.Flush the chute with water before starting to
transport the concrete.
(e) Wheel barrows can be effectively used for transporting concrete
horizontally over a short distance of about 60 meters. Provide a smooth
path for the wheelbarrows using planks or sheets to transport the concrete
without shaking or spilling.
171
Placing
(a) Preparation
1)
Do not place the concrete until the place of deposit has been thoroughly
inspected and approved. Check whether the formwork has been oiled
and the supports are rigid. Also, check whether the reinforcement ,
cover blocks, inserts and embedded plates have been properly secured
in position.
2)
Where concrete is to be bonded to a previous lift of concrete , clean the

surface thoroughly and chip the top to a depth sufficient to expose fresh ,
clean cut concrete without disturbing or loosening the coarse aggregate
3)
Keep the dry surface saturated with water for not less than 24 hours .
Before placing fresh concrete, remove the standing water from depressions
and spread about 1.5 cm thick mortar layer (in same proportion as in
original concrete but not greater than 1:2) over the contact surface of the
old concrete.
4)
When concreting has to be done against earthen surface, compact the

base by rolling or ramming and wet the surface by sprinkling water to
prevent excessive loss of moisture from the concrete.
b) During Placement
Deposit the concrete at, or as near as possible to its final position
lace the concrete in uniform layers. Avoid placing in large heaps or
P
sloping layers which will lead to segregation.
I n walls and columns no layer should be more than about450mm thick. As
more layer thickness make the concrete impossible to vibrate the bottom
layer and will lead to air entrapment at bottom and surface blemishes on
vertical surface.
In thin slabs place concrete thickness of 150mm.
here good finish is required on columns and walls restrict the pour
W
height to 2m per hour.
nsure every layer of concrete is fully compacted before placing successive
E
layer.
172
nsure the vibrator head penetrates the previous layer this will eliminate
E
layer lines.
Always make sure that you can see the concrete being deposited.
I n columns and walls the placing must be done in such a way that the
concrete does not strike the face of the formwork, similarly, avoid heavy
impact against reinforcement as the force could displace it.
Compaction
The object of compaction is to get rid of as much as possible of entrapped
air, down to less than 1% is the aim.(This does not apply with deliberate air
entrainment, but in that case the air is uniformly distributed and stable)
The amount of air is related to workability. Concrete with a slump of 75mm
contains about 5% air while concrete with 25mm has 20%.
This is why low slump concrete requires more vibration or longer time or more
poker needles compared to concrete with higher slump.
It is important to remove this entrapped air for the following reasons:
Voids reduces the strength of the concrete. Every 1% of entrapped air the
strength falls by about 5 to 6 % . So a concrete with 3% voids will be about
15 to 20% weaker than it should be.
Voids increased permeability, which in turn reduces the durability.
oid reduces the contact between concrete and reinforcement and other
V
embedded metals. The required bond will then not be achieved and the
reinforced member will not be as strong as it should be.
oids produces visual blemishes such as blowholes and honeycombing
V
and porosity on the struck surface.
Vibration
Rodding , spading-even using foot- are all ways of removing air from concrete
to compact it, but the best and quickest method is vibration.
When concrete is vibrated it is fluidized which reduces the internal friction
between the aggregate particle and removes the entrapped air , make them
to get packed well to become a dense member.
173
With a properly designed cohesive mix, segregation and bleeding will be

minimized. With an over-wet mix the larger aggregates may settle during
compaction with the result that a weak layer of laitance will finish up on top
surface.
Process of compaction
Points to remember in compaction

1.
Make sure the concrete surface being vibrated is seen. Light is need for
thin section columns and walls.
2.
Insert the needle quickly this makes the concrete liquefies and fill the
forms and allow the vibrator to penetrate to the previous layer.
3.
Compact concrete in place till the Entrapped air expels out
4.
Withdraw the needle slowly. The main thing is to see the hole made by
vibrator head is closed.
5.
Have proper lighting arrangement to see the concrete placed is

vibrated
6.
Excess vibration not to be done this may lead to Segregate the concrete
7.
Place the poker needle in not more than 500mm away from its last
position.
8.
Avoid touching the form face with poker needle. This will result in colour
variation
9.
Avoid touching the reinforcement by poker , this will displace the

174
reiniforcement and also will decrease the bond between the reinforcement
and concrete
10. Avoid moving concrete to flow using poker.
STOP VIBRATION WHEN
The concrete surface takes on a sheen
Large air bubbles no longer escape
You hear the vibrator change pitch or tone
You feel a change in vibration action
VIBRATING DONTS
Dont let a vibrator run very long outside concrete; it will overheat
Dont use a vibrator to move concrete horizontally
ont force pr push a vibrator into concrete it wont remain vertical and
D
may get caught in the reinforcement
Dont start a job without a spare vibrator
FINISHING
Initial finishing:
Strike off:
P
roperly done removes excess concrete and brings top surface to
grade
Start as soon as possible after placing concrete
End before bleed water appears
Straight edge uses can be of wood or magnesium
Straight edge
Use a side-to-side sawing motion while pulling forward
Tilt it slightly backward to create a single cutting edge
Keep about an inch of concrete in front to fill low spots
Make a second pass if the surface is not to grade
Pull concrete into end edge forms.
175
BULL FLOATS AND DARBIES

Use to level ridges and fill voids left by straightedge
Start immediately after strike off and finish before bleed water
appears
Use at right angle to the direction of strike off
P
ush the bull float with the front edge slightly off the surface to cut
bumps; pull the bull float with the back edge slightly off the surface to
fill voids
Use magnesium tools for sir entrained concrete
D
arbies serve the same purpose as bull floats but for smaller areas;
use in a sawing arc motion
WAITING PERIOD
B
egin further finishing when all the bleed water has evaporated and
concrete is firm enough to leave only inch foot prints
F
inishing while bleed water is present can cause surface crazing,
dusting or scalling
Final finishing
Edgers
Use to produce a clean slab edge that is less likely to chip
A
n edger is less likely to dig into concrete or leave a bumpy surface
if a trowel is used in a vertical sawing motion to dislodge aggregate
particles away from the edge forms
Run back and forth with the leading edge slightly raised
D
ont start in a corner and dont raise the edger off the concrete unless
the tool is in motion
U
se a wide edger for the first pass, then a narrow edger for the second
pass
Groovers
U
se to control crack location by cutting joints to a depth of atleast onefourth the slab thickness
P
ush the groover into the concrete then move it forward while applying
pressure to the back of the tool
176
A
fter joint is cut, turn the groover around, running it back over the cut
to give as smoother finish
For a straight cut, use a chalk line or a straight edge as a guide
Floats
U
se to remove imperfections and to bring mortar to the surface for
troweling
H
old flot flat and at arms length, moving it in awide semicircular
motion until surface is smooth
Use magnesium tools for air entrained concrete
More than one float pass may be required
Trowels
Use to produce a hard, dense surface
T
rowel only after floating, starting with a wide trowel then moving to
smaller trowels on the later passes
H
old trowel at a slight tilt at arms length and move it in a semicircular
motion , overlapping each pass by one half until surface finish is
smooth.
CURING
When cement is mixed with water, a chemical reaction takes place, called
hydration, it is this reaction which causes the cement and hence the concrete to
harden and then develop strength. This strength development can take place
only if the concrete is kept moist and at a favorable temperature, especially
during the first few days.
A properly cured concrete is superior in many ways. It is stronger and more
durable to chemical attack, but it is also more resistant to traffic wear and
more water- tight , further more the accidental knocks it is bound to receive
well probably cause less damage.
Cure concrete immediately after finishing by
Ponding
Build dike, then fill with water to cover the entire concrete slab
Avoid water or dike material that can stain the concrete
177
U
se curing water at a temperature within 20 F ( i.e -6 deg) of concrete
temperature
A
void premature or sudden release of ponded water which can
damage the surrounding environment
Sprinkling or fog spraying
K
eep the surface continuously wet, alternate wetting and frying causes
craze cracking
U
se low water pressure and flow to avoid washing away the fresh
concrete surface
U
se curing water at a temperature within 20 F ( i.e -6 deg) of concrete
temperature
Avoid if water runoff can damage the surrounding environment.
Using wet materials
Cover the concrete with wet burlap, straw, sawdust, or sand
Wet continuously, or cover with plastic sheet and wet frequently
Avoid materials that discolor concrete
Prevent materials from blowing away.
Using Plastic sheet or water proof paper
Lay flat , lap edges 6 inches, and cover exposed concrete edges
U
se minimum 4 mm thick plastic sheet white in hot weather and black
in cold weather
Dont use on architectural concrete
Secure covering to prevent concrete exposure
Using curing compounds
Apply after finishing when bleedwater disappears in slab or flat surface
I n vertical faces apply in two applications, at right angles to from a
continuous film
The efficiency will be 80% to that of water curing.
I f further painting or surface finishing required select compound which
will not harm secondary finishes. Otherwise paints will not stick to the
surface.
178
COMMON DEFECTS IN CONCRETE

FACTORS CAUSING DEFECTS
Causes of consolidation-related defects on formed concrete surfaces include:
Any defects in the finished concrete surface observed after removal of form
work
a. Design and construction-related causes
Difficult placement due to design of a member
Improper design, construction and maintenance of forms
Improper selection of concrete mixture proportions
Failure to adjust concrete mixture proportions to suit
Placement condition
Improper placement practices
Improper vibration and consolidation practices
Improper steel detailing
b. Equipment-related causes
Improper equipment
Improper equipment maintenance
Equipment failure (crane, pump, concrete plant)
Interruption of utility service
c. Material-related causes
Improper selection of release agent
Cement characteristics
Variation in mixture components
Inappropriate use of admixtures
Inappropriate use of release agents
d. Environmental causes
Extreme weather conditions
179
Types of surface defects

Surface defects which can result from ineffective consolidation procedures are
discussed below.
1
Honeycomb
Honeycomb is a condition of irregular voids due to failure of the mortar to

effectively fill the spaces between coarse aggregate particles. Where bridging
of the aggregate particles or stiffness of the mixture is a cause of honeycomb,
vibration may assist in overcoming the bridging by increasing the flowability
of the concrete. Factors that may contribute to honeycombing are: congested
reinforcement, insufficient paste content, improper sand-aggregate ratio,
improper placing techniques, quick setting on hot concrete, and difficult
construction conditions. Changes in mixture proportions to improve workability
may assist in reducing or preventing honeycombing.
2 Bugholes (Air surface voids)
Bugholes on vertical faces are normally caused by air bubbles, but occasionally
by water entrapped between the concrete mass and the form, especially in
sticky or stiff concrete mixtures of low workability which may have an excessive
sand and/or entrapped air content. Also, the use of vibrators of too large an
amplitude or the lack of complete insertion of the vibrator head may result in
increased air-void formation. Air voids vary insize from microscopic to about
1 in. (25 mm). Rarely will water create bugholes on formed surfaces. Excess
water normally manifests itself in other textural defects such as bleeding
channels or sand streaks on vertical formed surfaces. Bleed water voids can
form at the top of a column and on battered formed surfaces. Surface voids
can be minimized by procedures which are discussed in section 4.
3 Form-streaking
Form-streaking is caused by mortar leaking through form joints and may be
aggravated by over vibration from vibrators that are too powerful, or by using
forms that vibrate excessively during consolidation. Placing excessively wet or
high-slump concrete mixtures will result in more mortar washing out through
tie holes and loose fitting forms. Special care is sometimes required when
superplasticizers are used, as they tend to increase leakage at form joints and
in pump lines.
180
4 Aggregate transparency
Aggregate transparency is a condition characterized by a mottled coloring
on the surface which results from deficiencies in the mortar. It may result
when concrete mixtures have low sand content, dry or porous aggregates, or
high slump with some lightweight and normal weight aggregates. Also, high
density or glossy form surfaces may cause aggregate transparency.
5 Subsidence cracking
Subsidence cracking results from the development of tension when the
concrete settles after or near initial set.
The cracks are caused because the upper concrete bridges between the forms
while the lower concrete settles. These cracks may occur when there is an
insufficient interval between placement of concrete in columns and placement
of concrete for slabs or beams. They may also occur adjacent to block outs or
over reinforcing bars with shallow cover.
To prevent subsidence cracking, the concrete can be revibrated. Revibration
is most effective when done at the latest time at which the vibrator head
will penetrate the concrete under its own weight. Subsidence cracking over
reinforcing bars can be controlled by increasing concrete cover during the
design phase and by using well-consolidated, low-slump concrete.
6 Color variation
Color variation may occur within a placement if the concrete is not uniform
or is incompletely mixed. Vibrators inserted too close to the form destroy the
release agent or mar the form surface. External vibration used haphazardly
may also cause color variation. Furthermore, color variations may result from
nonuniform absorption and/or nonuniform application of the release agent.
7 Sand streaking
Sand streaking is a streak of exposed fine aggregate in the surface of the
formed concrete caused by heavy bleeding along the form. It frequently
results from the use of harsh, wet mixtures, particularly those deficient in 0.30
to 0.15 mm and smaller sizes. Sand streaking is controlled by the use of tight
181
forms and proper mixture proportioning, using well-graded fines to minimize

bleeding. Although the characteristics of portland cement and pozzolans, if
used, have some influence on bleeding, the grading of the fine aggregate is
of greater importance. Streaking tendencies increase when the ratio of sand
to cementing materials increases, such as in lean mixtures.
8 Layer lines
Layer lines are dark horizontal lines on formed surfaces which indicate the
boundary between concrete placements. Layer lines are caused by stiffening
or insufficient consolidation of the lower level due to lack of penetration of the
vibrator into the lower level.
9 Form offsets
Form offsets are usually caused by inadequate stiffness or anchorage of the
forms and can be aggravated by too high a rate of placement and/or using
too powerful a vibrator.
10 Cold joints
Cold joints frequently occur in concrete for many reasons. Cold joints can
often be avoided by contingency planning, back-up equipment, working to
keep the concrete surface alive, and working to vibrate into lower lifts.
Minimizing surface defects
To minimize the size and number of bugholes and other defects, arising out of
the consolidation the following practices should be followed:
Vibration period should be of sufficient duration
ibrator insertions should be properly spaced and overlapped and the
V
vibrator removed slowly
Each concrete layer should be consolidated from the bottom upward
Vibration periods should be increased when using impermeable forms
I nward sloping forms and other complex design details should be
avoided
Depth of placement layers should be limited
Vibrator should penetrate into the previous layer
182
ightening devices and gaskets to prevent leakage at form joints should

T
be provided as necessary
Placing ports should be designed into the forms as necessary
Bugholes can be minimized by the use, where practical, of a 64 mm diameter
vibrator of high frequency with medium to low amplitude. The vibrator should be
immersed in the concrete around the perimeter of the form without damaging
the form wall. Where reinforcement is placed near the form wall, the vibrator
must be inserted inside the reinforcement. Care should be taken to insure that
the vibrator has a sufficient radius of action to liquefy the concrete at the form
wall. Form vibration may be used to supplement the internal vibration. An
alternate procedure is to use a high frequency, low amplitude form vibrator.
Vibration procedures should be evaluated at the beginning of a project to
determine the vibration time for each type of vibrator for a given mixture.
In areas where voids are most prevalent, revibration may be used to reduce
bugholes. Revibration is more effective if it is done at the latest possible time
at which the vibrator head will penetrate the concrete under its own weight.
Greater benefits are obtained with wetter concrete mixtures, especially in the
top few feet of a placement where air and water voids are most prevalent.
Other measures, such as altering mix proportions, using super-plasticizers
and using smaller maximum aggregate size to improve workability should
also be considered as methods of minimizing surface defects. These measures
have often been successful, particularly when trying to consolidate concrete in
congested areas.
183
184
Small individual
holes, irregular ,
ranging up to 1inch
(25mm)In diameter
Sand or gravel
textured areas
lacking cement,
usually associated
with dark color on
adjacent surface
Unintended
discontinuity, off
coloured concrete
Air surface
voids
Form streaking
Cold joint
Stony surface with

air voids; lacking in
fines
Defects
Description
Honeycomb
Name
Internal
interference
Battered or
interfering
construction
Design of
member
Highly
congested
reinforcement,
narrow
section,
configuration
internal
interference,
reinforcement
splices
Leaking at
joints, tie
holes, etc.
Form face
impermeable,
poor wetting
characteristics,
form work too
flexible, use of
improper form
release agent
Leaking at
joints, severe
grout loss
Forms
Poor planning of
insufficient
backup
equipment
Excessive
release agent ,
high
temperature
Construction
conditions
High
temperature ,
wind,
reinforcement
too close to
forms,
accessibility
Too dry , early

stiffening
Low FM sand,
lean , sand with a
high FM, low
workability,
excessive cement
content or
pozzolana ,
particle
degradation ,
excessive sand ,
high air content
Excess water or
high slump
Causes
Properties of
fresh concrete
Insufficient fines,
low workability,
early stiffening,
excessive mixing
too
large
an
aggregate
for
placing conditions
Delayed
delivery
Excessive free
fall, excessive
travel
of
concrete
in
forms, too high
a
lift,
drop
chute omitted
or insufficient
length , too
small a tremie,
segregation
Too slow ,
caused by
inadequate
pumping rate,
undersized
bucket
Placement
Failure to vibrate into

lower lift. Insufficient
vibration
Excessive amplitude or
frequency
Too large an amplitude

, external vibration
inadequate, head of
vibrator partially
immersed
Vibrator too small , too

low a frequency too
small an amplitude ,
short immersion time,
excessive spacing
between immersions,
inadequate penetration.
Consolidation
185
Description
Variation
in colour
or shade due to
Short
cracks
separation
of fine
varying
width,
particlesincaused
more
often
by bleeding
horizontal
than
parallel to the
Description
Description
Description
Description
vertical
form face
Dark coloured
Short
Short
Short
Shortcracks
cracks
cracks
cracks
zones
between
varying
varying
varying
varyingin
in
in
inwidth,
width,
width,
width,
concrete
layers
more
more
more
more
often
often
often
often
Variation in colour
horizontal
horizontal
horizontal
horizontal
than
than
than
or shade duethan
to
Abrupt
to gradual
vertical
vertical
vertical
vertical
separation
of fine
surface caused
particles
irregularities
by
bleeding
parallel to the
Variation
Variation
Variation
Variation
in
in
incolour
colour
colour
colour
form
facein
or
or
or
orshade
shade
shade
shade
due
due
due
dueto
to
to
to
Dark
coloured
separation
separation
separation
separation
of
of
of
offine
fine
fine
fine
zones
between
particles
particles
particles
particlescaused
caused
caused
caused
concrete
layers
by
by
by
bybleeding
bleeding
bleeding
bleeding
parallel
parallel
parallel
parallelto
to
to
tothe
the
the
the
Abrupt
to gradual
form
form
form
formface
face
face
face
surface
Dark
Dark
Dark
Darkcoloured
coloured
coloured
coloured
irregularities
zones
zones
zones
zonesbetween
between
between
between
concrete
concrete
concrete
concretelayers
layers
layers
layers
Name
Sand streaking
Form
Form
Form
Formoffsets
offsets
offsets
offsets
Form offsets
Layer
Layer
Layer
Layerlines
lines
lines
lines
Sand
Sand
Sand
Sandstreaking
streaking
streaking
streaking
Layer lines
Form offsets
Layer lines
Subsidence
Subsidence
Subsidence
Subsidence
cracking
cracking
cracking
cracking
Sand streaking
Name
Name
Name
Name
Subsidence
Defects
Defects
Defects
Defects
cracking
Defects
Abrupt
Abrupt
Abrupt
Abruptto
to
to
togradual
gradual
gradual
gradual
surface
surface
surface
surface
irregularities
irregularities
irregularities
irregularities
Dark
Dark
Dark
Darkor
or
or
or
light
light
light
lightareas
areas
areas
areas
Short
cracks
of
of
of
ofsimilar
similar
similar
similar
size
size
size
size
and
and
and
and
varying
in
width,
shape
shape
shape
shapeto
to
to
tothat
that
that
thatof
of
of
ofthe
the
the
the
more
often
coarse
coarse
coarse
coarseaggregate,
aggregate,
aggregate,
aggregate,
horizontal
than
mottled
mottled
mottled
mottledappearance
appearance
appearance
appearance
vertical
Aggregate
Aggregate
Aggregate
Aggregate
Subsidence
transparency
transparency
transparency
transparency
cracking
Name
Dark or light areas

of similar size and
shape to that of the
coarse aggregate,
Description
mottled
appearance
Aggregate
Defects
transparency
mottled appearance
Internal
Internal
Internal
Internal
interference
interference
interference
interference
Internal
interference
Design
Design
Design
Designof
of
of
of
member
member
member
member
Internal
Interference
Interference
Interference
Interference
interference
to
to
to
toaccess
access
access
access
Interference
to access
Design of
member
Interference
to access
Design of
member
porous ,
excessive coarse
aggregate ,
excessive slump
with light weight
concrete
Too flexible,
Low sand
Causes
high density
content,
surface finish
gapgraded,
aggregate
dryofor
Construction
Properties
Forms
Placement
porous
,
conditions
fresh
concrete
excessive coarse
Too
Too
Too
Tooflexible,
flexible,
flexible,
flexible,
Low
Low
Low
Low
sand
sand
sand
sand
Poor
thermal
Insufficient
Low
sand,
high
Too rapid
aggregate
,
high
high
high
highdensity
density
density
density interval between
content,
content,
content,
content,
insulation,
water
content
excessive
slump
surface
surface
surface
surface
finish
finish
finish
finish
gapgraded,
gapgraded,
gapgraded,
gapgraded,
irregular
topout of
with
light weight
aggregate
aggregate
aggregate
aggregate
dry
dry
dry
dryor
or
or
or
shape
columns and
concrete
porous
porous
porous
porous, ,,,
restraining
placement of
Causes
excessive
excessive
excessive
excessivecoarse
coarse
coarse
coarse
settlement,
slab or beam,
aggregate
aggregate
aggregate
aggregate, ,,,
excessive
low humidity
excessive
excessive
excessive
excessiveslump
slump
slump
slump
absorbency
Construction
Properties
of
Forms
Placement
with
with
with
withlight
light
light
light
weight
weight
weight
weight Too
Low
Low
Lean
mixture,
rapid for
conditions
fresh
concrete
concrete
concrete
concrete
concrete
absorbency
temperature,
over
sanded
type of mix
Poor thermal
Insufficient
Low
sand,mix,
high
Too rapid
wet
mixtures
bleeding
Causes
Causes
Causes
insulation,
interval between Causes
water
contentin
sand
deficient
irregular
topout of
fines, low air
shape
columns
and
content of
Construction
Construction
Construction
Construction
Properties
Properties
Properties
Properties
of
of
of
Forms
Forms
Forms
Forms
Placement
Placement
Placement
Placement
restraining
placement
of
conditions
conditions
conditions
conditions
fresh
fresh
fresh
freshconcrete
concrete
concrete
concrete
settlement,
slab
or beam,
Insufficient
Wet mixture with
Slow
Poor
Poor
Poor
Poor
thermal
thermal
thermal
thermal
Insufficient
Insufficient
Insufficient
Insufficient
Low
Low
Low
Lowsand,
sand,
sand,
sand,
high
high
high Placement,
Too
Too
Too
Toorapid
rapid
rapid
rapid
excessive
low
humidity
planning,
high
tendency
to high
bleed
lack
insulation,
insulation,
insulation,
insulation,
interval
interval
interval
interval
between
between
between
between water
water
water
watercontent
content
content
content
absorbency
temperature
of equipment
irregular
irregular
irregular
irregular
topout
topout
topout
topout
of
of
of
of
Low
Low
Lean mixture,
Too
rapid for
or
manpower
shape
shape
shape
shape
columns
columns
columns
columnsand
and
and
and
absorbency
temperature,
over sanded
type of mix
Inadequate
Excessive
Rate too high
restraining
restraining
restraining
restraining
placement
placement
placement
placement
of
of
of
of
wet
mixtures
bleeding
mix,
stiffness
or
retardation
settlement,
settlement,
settlement,
settlement,
slab
slab
slab
slabor
or
or
orbeam,
beam,
beam,
beam,
sand
deficientofin
anchorage,
mixes
excessive
excessive
excessive
excessive
low
low
low
lowhumidity
humidity
humidity
humidity
fines,
low air
weak
forming
absorbency
absorbency
absorbency
absorbency
content
material,
Low
Low
Low
Low
Low
Low
Low
Low
Lean
Lean
Lean
Leanmixture,
mixture,
mixture,
mixture,
Too
Too
Too
Toorapid
rapid
rapid
rapidfor
for
for
for
irregular
absorbency
absorbency
absorbency
absorbency
temperature,
temperature,
temperature,
temperature,
over
over
over
over
sanded
sanded
sanded
sanded
type
type
type
type
of
of
of
ofmix
mix
mix
mix
Insufficient
Wet
mixture
with
Slow
lumber, poor
wet
wet
wet
wetmixtures
mixtures
mixtures
mixtures
bleeding
bleeding
bleeding
bleeding
mix,
mix,
mix,
planning,
high
tendency
tomix,
bleed
Placement, lack
carpentry
sand
sand
sand
sanddeficient
deficient
deficient
deficientin
in
in
in of equipment
temperature
fines,
fines,
fines,
fines,low
low
low
lowair
air
air
air
or manpower
content
content
content
content
Inadequate
Excessive
Rate too high
stiffness or
retardation
of
Insufficient
Insufficient
Insufficient
Insufficient
Wet
Wet
Wet
Wet
mixture
mixture
mixture
mixturewith
with
with
with
Slow
Slow
Slow
Slow
anchorage,
mixes
planning,
planning,
planning,
planning,high
high
high
high tendency
tendency
tendency
tendency
to
to
to
tobleed
bleed
bleed
bleed Placement,
Placement,
Placement,
Placement,lack
lack
lack
lack
weak forming
temperature
temperature
temperature
temperature
of
of
of
ofequipment
equipment
equipment
equipment
material,
or
or
or
ormanpower
manpower
manpower
manpower
irregular
Inadequate
Inadequate
Inadequate
Inadequate
Excessive
Excessive
Excessive
Excessive
Rate
Rate
Rate
Ratetoo
too
too
toohigh
high
high
high
lumber,
poor
stiffness
stiffness
stiffness
stiffnessor
or
or
or
retardation
retardation
retardation
retardationof
of
of
of
carpentry
anchorage,
anchorage,
anchorage,
anchorage,
mixes
mixes
mixes
mixes
weak
weak
weak
weakforming
forming
forming
forming
material,
material,
material,
material,
irregular
irregular
irregular
irregular
lumber,
lumber,
lumber,
lumber,poor
poor
poor
poor
Excessive
Excessive
Excessive
Excessiveamplitude,
amplitude,
amplitude,
amplitude,
nonuniform
nonuniform
nonuniform
nonuniformspacing
spacing
spacing
spacingof
of
of
of
immersion
immersion
immersion
immersion
Excessive amplitude,
nonuniform
spacing of
Lack
Lack
Lack
Lackof
of
of
ofvibration,
vibration,
vibration,
vibration,
immersion
failure
failure
failure
failure
to
to
to
topenetrate
penetrate
penetrate
penetrateinto
into
into
into
previous
previous
previous
previouslayer
layer
layer
layer
Excessive
Excessive
Excessive
Excessivevibration
vibration
vibration
vibration, ,,,
Excessive
Excessive
Excessive
Excessive
amplitude
amplitude
amplitude
amplitude, ,,,
Lack of vibration,
Over
Over
Over
Over
manipulation
manipulation
manipulation
failure
tomanipulation
penetrate
into
previous layer
Lack of vibration,
Insufficient
Insufficient
Insufficient
Insufficient
vibration
vibration
vibration
vibration
failure
to penetrate
into
previous layer
Excessive vibration ,
Excessive amplitude ,
Excessive
amplitude,
Over manipulation
nonuniform spacing of
immersion
Consolidation
Consolidation
Consolidation
Consolidation
Consolidation
Excessive
vibration ,
Excessive amplitude ,
Insufficient
vibration
Over manipulation
Excessive
Excessive
Excessive
Excessiveor
or
or
or
external
external
external
external
Insufficient
vibration
vibration;
vibration;
vibration;
vibration;over
over
over
overvibration
vibration
vibration
vibration
of
of
of
oflight
light
light
lightweight
weight
weight
weightconcrete
concrete
concrete
concrete
Consolidation
Excessive or external
vibration; over vibration
of light weight concrete
SPECIAL CONCRETE
Concrete used for ALUFORM and Tunnel form has to be designed considering
the following to avoid surface defects and to get form finish
The concrete mix should be slightly over sanded and cohesive
he concrete mix at placement should have a slump of 150mm to 200
T
mm (like tremie concrete)
he maximum size of aggregate may be 12.5mm or 10mm considering
T
the reinforcement, electrical conduits and electrical boxes and other
boxouts provided
he concrete should attain the required strength of 15 N/mm2 at 36
T
hours for Mivan formwork and 8 to 10 N/mm2 after 18 hours for tunnel
forms
he cubes used to check the form removal strength shall be cured along
T
with structure and tested at specified time.
hen Self compacting concrete is used the concrete shall have a flow of
W
600 mm to 700mm flow at placement.
oncrete placement shall be commenced from pouring in walls and
C
finished along with slab covering room by room
hen concrete is placed in walls the form work shall be shirked with
W
wooden mallet to ensure air removal from surface
xcess malleting to be avoided after full placement in walls , if continued
E
will lead to formation of mild gap between form and concrete and will
entrap bleed water and lead to bug holes.
hile placing in walls having windows, electrical boxes concrete need to
W
be placed from one side ensuring the concrete placed flow to the other
side and get lifted up passing boxes or cutouts. Both side placement will
lead to air entrapment under boxes and lead to void or cavity.
186
Prestressing
INTRODUCTION:
The prestressing and precasting of concrete are inter-related features of
the modern building industry. Prestressing concrete is the application of
compressive force to concrete members and may be achieved by either pretensioning high tensile steel strands before the concrete has set, or by the
post-tensioning the strands after the concrete has set.
DEFINITIONS:
Prestressing of concrete is defined as the application of compressive stresses
to concrete members. Those zones of the member ultimately required to carry
tensile stresses under working load conditions are given an initial compressive
stress before the application of working loads so that the tensile stress
developed by these working loads are balanced by induced compressive
strength. Prestress can be applied in two ways.
1. Pre- tensioning
2. Post-tensioning.
1. Pre-tensioning:
Pre-tensioning is the application, before casting, of a tensile force to high
tensile steel tendons around which the concrete is to be cast. When the
placed concrete has developed sufficient compressive strength a compressive
force is imparted to it by
releasing the tendons, so
that the concrete member
is in a permanent state of
prestress.
2. Post- tensioning:
Post-tensioning
is
a
method of reinforcing
concrete or other materials
with high strength steel
187
strands or bars, typically referred to as tendons. Post-tensioning applications

include office and apartment buildings, parking structures, bridges, stadiums,
soil anchors and water tanks.
Post tensioning is the application of a compressive force to the concrete at
some point in time after casting. When the concrete has gained strength a
state of prestress is induced by tensioning steel tendons passed through ducts
cast in to the concrete, and locking the stressed tendons with mechanical
anchors. The tendons are then normally grouted in place.
ADVANTAGES OF PRESTRESSING
Minimizes the concrete crakes.
Allows reducing beam depth.
Allows greater degree of loading than any structural material.
Lighter elements permit the use of longer span.
Ability to control deflection in beams and slab.
Permits efficient usage of steel and reduces cost.
Speed in construction.
APPLICATION
Bridges
Nuclear Structures.
188
Building frames and floor slabs.

Marine and waterside Structures.
Ground anchor.
Heavy lifting.
Foundation.
Materials
Management
1) HT Strand
2) Anchorages
189
3) Wedges:
4) Sheathing:
190
MATERIAL ORDERING:
The followings are to be specified in MR.
Client Specification
IS code references
Type of material
Delivery schedule
Type of packing
RECEPIT AT SITE:
H.T. Strand:
Check the following:
Size of Strand.
Coil No/Heat No.
IS Specifications and class of strand.
Weight/ Length.
Test certificate.
PT Hardware:
Check for the test/mill certificate
IS Code references
Size/ dimensions.
Quantity
Visual inspection for any crake
REFRENCE STANDARDS &CODES:
HT STRAND : IS : 14268 -1995
IS: 6006 -1983
ASTM A 146 -1998
TEST FOR SHEATHING : IRC : 18 -2000
191
TESTING FOR PRESTRESSING SYSTEM :
BS 4447 -1973
GROUTING :
IRC : 18 -2000
PRESSURE GAUGE TESTING :
IS: 3624 -1987
Elongation & Modified Elongation Calculations:

a) Elongation Calculation:
1.
Design load in N--- P
2.
Length of Tendon in mm --- L
3.
Area of Strand in mm2 --- A
4.
Youngs Modulus in N/ mm2 --- E
Elongation (e) = PxL / AxE in mm
b) Modified Elongation Calculation:

1.
Area of Strand in mm2 --- A
2.
Youngs Modulus in N/ mm2 --- E
3.
Elongation in mm --- e
4.
Modified Area of Strand (as per TC) in mm2 --- MA
5.
Modified Youngs Modulus in (as per TC) N/ mm2 --- ME
Modified Elongation (Me) = ex AxE / MAxME in mm
Jack Pressure Calculation:

a) Single-pull Stressing:
1.
Design load per Strand Kg
2.
Losses due to Jack Efficiency % (add as per Jack Calibration Report)
3.
Losses due to Anchorages % (add as per System Suppliers Report
4.
Load per Strand including losses Kg --- P
5.
Jack Ram Area Cm2 --- JA
Jack Pressure (JP) = P/JA in Kg/Cm2

192
b) Multi-pull Stressing:
1.
Design load per Strand Kg
2.
Load per Tendon (as per the type) Kg
3.
Losses due to Jack Efficiency % (add as per Jack Calibration Report)
4.
Losses due to Anchorages % (add as per System Suppliers Report)
5.
Load per Tendon including losses Kg --- P
6.
Jack Ram Area in cm2 --- JA
Jack Pressure (JP) = P/JA in Kg/cm2
Losses in Prestress:
Losses due to Elastic Shortening of Concrete
Creep in Concrete (Creep Strain)
Shrinkage in Concrete
Relaxation of Prestressing Steel
Losses due to seating of Anchorages
Friction Losses
Properties of HT Strand (IS: 14268 - 1995):
Class
Nominal
Tolerance
of HT
diameter
Dia (mm)
Strand
(mm)
in
Nominal
Nominal
Breaking
0.2% Proof
Minimum
Modulus of
Area
Mass
Strength
Load (KN)
Tensile
Elasticity
(mm2)
(Kg/M)
(KN)
Strength
(N/mm2)
(N/mm2)
II
9.5
+/-0.4
51.6
0.405
89.0
80.1
11.1
+/-0.4
69.7
0.548
120.1
108.1
12.7
+/-0.4
92.9
0.73
160.1
144.1
15.2
+/-0.4
139.4
1.094
240.2
216.2
9.5
+0.66 / -0.15
54.8
0.432
102.3
92.1
11.1
+0.66 / -0.15
74.2
0.582
137.9
124.1
12.7
+0.66 / -0.15
98.7
0.775
183.7
165.3
15.2
+0.66 / -0.15
140
1.102
260.7
234.6
1860
195000
1860
195000
Methodology of Post-tensioning work:

Post-tensioning work is divided into three major activities. The general
methodology is given below.
193
Methodology of Post-tensioning work:

Post-tensioning work is divided into three major activities. The general
methodology is given below.
1.
Profiling.
2.
Stressing.
3.
Grouting.
1) Profiling:
ead the drawings and identify type of tendons, layout, locations, and
R
number of strands per tendon, sequence of laying, number of tendons per
pour, etc.
alculate the materials requirement such as Tube Units, Bearing Plates,
C
Wedges, Sheathing and Prestressing Steel (HTS).
alculate the cut length of Strand inclusive of Jack Grip length & profile
C
for each tendon and prepare Strand cutting schedule as per drawing. HT
Strand must be cut by using cut-off wheel/abrasion blade.
T Strand shall be uncoiled using coil dispenser and it should not contact
H
soil or dust while cutting.
ark the Tendons as per Tendon layout drawing, after the completion of
M
formwork& reinforcement.
ix the fabricated tendon support bars (bar chairs) rigidly at every 1m
F
(max.) interval according to the tendon layout and profile drawings.
L ay the sheathing over the tendon support bars as per the tendon layout
drawing and jointhe ducts using couplers and seal the joint using selfadhesive tape.
hread therequired number of Strands into Sheathing according to the
T
Tendon type (strand schedule) and tie thesheathing with Bar Chairs using
Binding wires rigidly.
rofiling of Tendons, both horizontally and vertically as per drawingsand
P
arresting it rigidly to avoid any disturbances in profile during concreting.
ix the Stressing anchorages and make Dead-end anchorages position as
F
per the layout drawing. Fix the Grout vents at end portions and Air vents
194
at high profile locations and seal it properly.

ie Bursting and Spiral reinforcements at the anchorages zones as per the
T
details given in drawing.
inal checking of all Tendons for profiling, supporting and sealing after the
F
completion of reinforcement and formwork works and before concreting.
2) Stressing:
tressing shall be carried out only after the concrete has attainedthe
S
required Compressive Strength and age of concrete as specified in the
drawing.
heck the Stressing equipments and hoses before stressing to ensure
C
proper/smooth functioning.
T Strand/Wire/Bars shall be completely cleaned (oil, dust & etc.) for
H
gripping of Jacks. Stressing can be carried out stage by stage if required,
as per drawing.
alculate the Elongation or Modified Elongation for each tendon as per
C
the physical values in TC.
alculate the Jack Pressure for the Design Load including Jack & Anchorage
C
losses.
tressing shall be carried out only as per the specified sequence. Load
S
shall be applied to the tendons by using calibrated hydraulic pumps and
jacks and monitored through calibrated Pressure gauges.
ix the Bearing plate to the tube unit and lock it by wedges and mark
F
a reference point on Strand to measure elongation. Stressing can be
performed in single / multi strokes depend on Jack piston length.
ix the Hydraulic Jack (Mono/Multi) at stressing end (Single/Double) and
F
ensure proper seating of jack with bearing plate and also connect the Jack
& Pump by hydraulic hosepipes.
pply the calculated pressure (load) gradually in incremental basis on
A
each strand or tendon by using hydraulic Jack and Pump. Apply jack
pressure at both ends simultaneously for double-end stressing.
hile applying load check for required elongation & jack pressure during
W
stressing and also note the Jack pressure & Elongation reading at every
interval / stage in stressing format.
195
ompute the total Jack Pressure applied and the total elongation arrived
C
during stressing.
I f elongation reached, but pressure not reached apply 5% additional
elongation. If pressure reached, but elongation not reached apply 5%
additional pressure.
fter applying the additional pressure / elongation, if the Stressing result
A
is within +/-5%, release the jack pressure slowly and then proceed for
next stressing.
I f the stressing result / value is more than +/-5% inform the Design
Engineer for further instruction. Same method shall be followed for all
other Strands / Tendons.
2 hours after the completion of stressing of all tendons, cut the strands
1
leaving 25mm from the face of wedges by using angle grinder.
fter cutting fill the recess pockets (Stressing pocket) in layers using
A
approved materials.
3) Grouting:
fter the setting / curing time of recess pockets, flush the tendons
A
(sheathing) completely by water and then by compressed air.
otable water and OPC Cement should be used for preparation of grout.
P
Suitable admixture (Non-Aluminium / Non-Chloride based) may be
added to the grout as per specification.
Fix the valves at all grout and air vents and also fix the pressure gauge.
Mix Water followed by Cement of ratio 0.40 in the grouting machine.
he grout shall be mixed in mixture for 2-3 minutes and until pumping of
T
grout.
rout should be colloidal mixture and free from any lumps and it should
G
passed through sieve.
ump the grout into the tendon through grout vent pipe (inlet) and release
P
the air inside the tendon through air vents.
lug all air vent pipes and also the outlet vent pipe after consistent grout
P
is passed.
After plugging all the vents pipes tightly, built the pressure of 5kg/cm2
196
and maintain for one minute. Then close the inlet valve also. The same
method shall be followed for all other tendons.
routing should be performed continuously to avoid grout setting. Any
G
breakage occurred during grouting, flush the tendon with water and
compressed air and do fresh grouting.
Clean the vicinity by water after the grouting is completed.
Cut all vent pipes projecting outside the surface after the grout is set.
PRESTRESSING EQUIPMENTS
197
GROUTING MACHINE
TENDON PROFILING:
TENDONS LAID IN FLAT SLAB
PROFILED TENDONS IN BEAM

(MULTI 19T15 SYSTEM)
198
CASE STUDY
Problem:
Breaking of concrete near anchorage area.
Probable reason:
Poor quality of concrete
Improper vibration of concrete near anchorage zone
Poor workmanship
Dead end slippage
199
Strand snap
Actual reason:
Honey comb near anchorage area
Improper vibration.
Correct alignments of anchorage
Remedial action:
De-stress the tendon
Chip the crack area and remove the loose concrete.
Remove the broken anchorage
Fix the new anchorage and connect the duct.
Fill the area with epoxy or approved material
After getting the strength stress the tendon.
Note:
All this remedial works carried out the consultation with
Designer.
200
Photos
201
202
Introduction
Environment,
Health and Safety
Larsen & Toubro , Health, Safety & Environment Department had been
certified ISO 9001:2000. We are the first company in India to have such
accreditation. The companys management gives utmost importance to safety
in the companys function. The Safety Engineering Department has bagged
many commendations from various clients.
GOALS
Maintaining a safe and healthy working environment.
Preventing fatalities and lost time injuries.
reventing damage to the equipment, facilities and potential effects on
P
progress.
Eliminating risk to the environment.
No fires.A Safe and Productive Project, in Scheduled time.
Safety Rule and Procedure.
Rules:
Head Protection:All personals engaged for this job shall wear Safety Helmet of Class B type.
Hand Protection:Appropriate Hand Gloves will be used for Materials handling , Concreting,
Welding , Grinding , Gas cutting , Chemical Handling & Electrical work.
Eye Protection:Suitable goggles must be ensured for the personnel deployed for Welding
(Face Shield), Grinding, Gas cutting, Concreting, Chipping etc. Staff should
wear safety spectacle.
Ear Protection:The personnel engaged in the noise zone such as Compressor Operator.
Pneumatic Vibrators & Breakers, DG Operator etc. will be equipped with
suitable ear protection.
203
Protection from Dust & other poisonous gases:-

Suitable nose mask, face shield / cloth are to be used by the individuals to
protect them from dust, fumes, poisonous and toxic gases.
Body Protection:Appropriate body protection like Boiler Suit, Aprons must be used by the
concern personnel at site.
Fall Protection:All personnel working at heights must use the safety belt.
Foot Protection:Safety Shoe ought to be worn by all who enters the site.
Housekeeping:
1.
This is to be maintained by the individual at his work area.
2.
Papers, cotton waste or any other rubbish should be thrown in the

dustbin.
3.
Every gang should keep their materials stacked properly.
4.
Do not keep materials obstructing the path.
Electrical:
1.
Only electricians are allowed to give electrical connections.
2.
Electrical cables are to be kept minimum 7 high or buried in the

ground.
3.
Bare electric wire insertion in socket is prohibited.
Plant & Machinery:

a.
Only qualified operators are allowed to operate winches, cranes, trailors

& any vehicles. They should have license as per local government rules.
b.
Cranes & equipments shall be used after inspected & approved by the
Safety engg. Dept.
204
Others:
I t is preferable to have one entrance to enter the chimney. One security
guard shall be posted to prohibit anyone entering without helmet and
trespassers.
T
he entrance shall be sheltered to a length of 15m outside the chimney
and inside upto R. G. Hoist so that entrant will be saved from falling
material.
B
arricade is required around the shaft circumference at a distance of
10m.
I nside the chimney, at the locations where perpendicularly is checked
by laser beam, is to be sheltered with a small hole.
D
eploy minimum number of workmen on the platform and as far as
possible have them scattered.
S
afety posters and caution boards shall be displayed on the platform
and at ground level.
Intercom for communication is very much required.
I t is important to give a safety talk to workers by the concerned engineer
briefing on procedures before the slipform starts.
A
viation warning lights are necessary when the structure reaches
height of 50M
It is part of each employees job to report all unsafe act / unsafe
condition and accident immediately to his supervisor.
At No Smoking areas smoking is prohibited.
Horseplay like practical jokes, running etc. is strictly to be avoided.
Observe all working & hazard notice.
A
ll are requested to follow instructions from their immediate supervisors.
If instructions are not clear or are confusing, the employee has a
responsibility to clarify with the supervisor and obtain clear instructions
before commencement of works.
A
ppropriate fire extinguishers are to be kept on the platform. The
distance to reach a fire extinguisher should be maximum 25m.
205
PROCEDURE:
Safety Committee:
Safety Committee is formed at site whose function is to troubleshoot safety
problems and conduct a weekly safety walk down . Not more than five to six
members would be in the committee and they are mainly section in charges.
Safe Work Method.
A written Safe Work Method for a job is prepared by the Safety Personnel
in consultation with the concerned engineers. The Work Method helps to
foresee the risk involved in the job, take precautionary action for the risk
involved and plan the materials required for the safety cause. The safe work
method is methodically done as followed:
a.
Approach Safety.
b.
Work Method Safety.
c.
Work area Safety.
d.
Men Material and Machinery.
On receiving the safe work method, the line engineers brief it to their
subordinate and implement them.
Safety Meeting:
Safety meeting shall be held once in a week for staff and sub- contracors
representatives. The meeting is convened by the safety engineer and chaired
by the project manager / site superintendent. Minutes of the meeting are
minuted in L&Ts Safety Meeting Format. Copies are sent to GM/ DGM/ RSC,
PM/ Site staff, once in a fortnight.
Screening System:
All workmen before deploying at site shall be screened by the site in charge/
engineer and safety engineer.
Orientation :
Orientation on safety is given to the new staff and workmen before they go
to work place.
206
Training:
Training programmes conducted by the Safety engineer for staff and
workmen
General Safety
Safety in Welding & Gas Cutting Operation
Material Handling
Fire Safety
Working at Heights
Electrical Safety
Work Permit systems
Personnel Protective Equipments & Job based training programmes
Safety Inspection:
Daily Safety Inspection is conducted by safety engineer. .Weekly Safety
Inspection by the safety committee and the findings are minuted.
Tool Box Meeting / Safety Task Assignment (STA):
Tool box meeting is conducted everyday by gathering the workmen before
starting the job. Concerned engineer talks for 5 to 10 minutes on Safety to the
workmen. In Tool Box Meeting, general safety, case studies or job knowledge
is imparted to the workmen.
STA is conducted whenever a new activity is taken up and the concerned
engineer details the workmen the safe work method to carryout the job. This
safety procedure helps to keep the safety consciousness among the workmen
at constant level.
Ladder Inspection:
The ladders used in the site are numbered and inspected once in a month.
The inspection is recorded in a register.
207
Scaffolding:
Scaffolding is erected by an experienced scaffolders and under the supervision
of a competent authority. Tag system shall be followed to indicate whether the
scaffold is permitted to use or not. Red tag indicates, only scaffolders are
allowed to work on it and the scaffold is not ready to use. Green tag indicates
the scaffold is for use by all.
Wire ropes, Tools & Tackles inspection:
A competent person identified at the site first inspects the above materials.
The said materials are coded and coloured to indicate whether they are good
for use. Visual Inspection is carried out once in a month and recorded the
findings.
Electrical Inspection:
Monthly Inspection is done for the total electrical installation at the site and
recorded.
Equipment fitness certificate:
Any equipment arriving to the site is inspected and authorized by the
P & M engineer and safety engineer on its fitness to use. Based on their
recommendation the equipment is deployed / rejected / used after a minor
repair. The inspection is recorded.
Fire Safety:
1.
Once in three months the fire extinguishers installed in the site premises
shall be maintained and recorded in a register.
2.
Monthly inspection shall be conducted for the smoke detectors in the

portocabin / Site Office, to ensure its working condition.
Work Permit System:

All the relevant work permit systems shall be followed as per L&T / Clients
procedure. viz,
a.
Excavation Permit.
b.
Electrical work Permit.
c.
Confined space entry permit. Etc.

208
Accident Reports, Investigation and Analysis:

All minor injuries should be brought to the notice of the Site management and
recorded.
Lost Time Accidents, fatal accident, vehicle accident or damage to L&T plants,
facilities or equipment should be reported to the site management. The
contact phone nos. is given in Emergency Response Program. Subsequently,
reports of the accident shall be given in the L&T format.
All accidents and near misses shall be investigated by the Safety engineer &
Safety committee of the site and recorded.
Safety Motivations:
The company has the following reward schemes to encourage the employees
to follow safety.
1.
Million Safe Manhours: The jobsite which achieves One million safe
manhours or more a certificate of merit is given to the jobsite signed by
the President of the company.
2.
Annual Safety Award: Given to the Best Safety performed jobsite in the
Company as a whole.
3.
Best safety workman: This is given at site level on monthly basis. The site
safety committee selects the most safety conscious workman among the
workforce , for the month and rewards him
HEALTH AND WELFARE

a) First Aid : First Aid Facility to be available in accordance with L&T policy
requirement. It is intent of the L&T management that the project is
self sufficient in terms of dealing minor first aid injuries and medical
requirements. In the event of a Serious Injury or an individual requiring
professional medical advice and care, are referred immediately to the
local hospital.
b) Sanitary Facilities: Adequate sanitary facilities are provided for the
number of personnel present at site. Administration department will
maintain it in hygienic condition.
209
c) Working hours: Working hours may vary due to time of year and
particular peak workloads. In general work will be restricted to a ten
hours day with one-hour lunch break. Working on Fridays, the normal
rest day is discouraged but may be required from time to time.
Welfare facilities encompass both the site facilities and those of the company
accommodation.
SAFETY IN SLIPFORM:
GENERAL:
1.
Wearing safety helmet by all will be imperative.
2.
Preferably one entrance will be there to enter the structure.
3.
The entrance will be sheltered to a length of 5 mtrs, from outside the

structure so that entrants will be saved from falling objects.
4.
Barrication will be there around the structure to a distance of 10 mtrs.
5.
Minimum number of workmen will be deployed on the platform and as

far as possible have them scattered.
6.
SMOKING IS PROHIBITED on the platform.
7.
Fire extinguishers will be kept on the platform and the distance to reach
a fire extinguisher will be max. of 25 mtrs.
8.
Safety posters and caution boards will be displayed on the platform and
at ground level.
PLATFORM:
1.
The working platforms will be checked by a competent person, for its

stability and reliability.
2.
Platforms will have handrail and toe board.
3.
The recommended size of plank is 1800 x 250 mm width x 50 mm

thick - preferable variety is hardwood, for working platform and hanging
scaffolds.
4.
Both inside and outside hanging scaffold platforms will be covered with
safety nets.
210
5.
Access ladders will be provided to access top platform and hanging

platform.
ELECTRICAL:
1.
All electrical equipment will be earthen.
2.
Earth leakage circuit breaker (ELCB) will be fixed.
3.
The electrical cable will be neatly traced along the platform and
handrail.
REINFORCEMENT GANG:
1.
Experienced and designated operator for winch operation will be

deployed.
2.
The access to pick the rebar from the winch bucket will be safe and easy
reach.
3.
Rebar will be uniformly distributed on the platform and they will be

placed on sleepers such that the load is transferred to the spider beam
and not to the planks.
4.
The quantum of RF rods stacked will not be more than a shifts

requirement.
HOUSE KEEPING:
1.
Housekeeping on platform will be maintained stringently. No material

will be dropped from height.
2.
The shutter cleaning gang will be instructed to clear the platform at the
end of the shift and the collected debris will be brought down.
3.
Bit rods cut by gas cutter or electrode bits generated by welders will be
collected by the respective helpers and brought down at the end of each
shift.
Safety is everybodys business. Slipform in-charge, in co-ordination with site

safety engineer should conduct safety demonstration / meetings.
1.
Daily pep talk.
2.
Weekly safety meeting for staff, departmental, subcontractor and other

workmen.
211
3.
Fire extinguisher demonstration.
4.
Check on all safety appliances.
PLANT & MACHINERY:

Trial run for all plant and machinery before starting slipforming.
Operators for all machinery and training the operators.
Sufficient spares to run the machinery on a continuous basis.
Mandatory safety checks on machinery.
Back up in case of breakdown.
M
aintenance record for machineries duly checked and counter signed
by the concerned staff and operator.
GENERAL SAFETY
Toe boards.
Tying of safety nets.
Hand rails.
Fire extinguishers (DCP) at top and bottom.
First aid box at top.
Emergency lights.
Safety signboards.
Protective shed.
Prevent overloading of safety nets. Periodic cleaning is necessary.
Wind protection cloth.
Safety belts, safety helmets, goggles and gloves to be used properly.
Proper earthling. Earthing for lights (ELCB)
P
roper illumination at the top as well as around the slipform
structure.
Built in safety systems in the equipment to be tested.
Lightening arrestors./ Aviation lamps wherever required.
212
This Handbook is the property of Larsen & Toubro Limited Construction Group and must
not be passed on to any unauthorized person or body for reproduction or reference
without prior permission sought in writing from L&T ECC Division.
Engineering Construction & Contracts Division

Mount Poonamallee Road,
Manapakkam, Chennai 600 089.
Phone: 044-22526561
August 2010

Handbook Foundation Form Work Rebar Concrete

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Hand Book on Foundation,

Formwork, Rebar &

ALUMINIUM FORM WORK

Hook & Bend Allowance........................................................................92

Driven cast in-situ piles...................................................................130

Points to remembered in Compaction..................................................174

Slab Corner Internal

BEAM SPLICE BAR

BEAM SPLICE BAR

Slab corner Internal

Flow Chart for

If work front is ready

19a, 19b, 19c, 19d

Activity for the Flow

1. Receive Aluform materials.

Kgf / cm 2 - when releasing the form.

Kgf / cm 2 - when coming out from the form.

20 Kg / cm 2 - after 24 hours since pouring.

Check starter for the correctness in level and diameter.

form supports with pre assembled

Assembly of Stair Tower:

Uniform layer of concreting.

Regular cleaning of shutters.

Penetration testing of concrete, for setting time.

Freeness of tapered sleeves.

Periodical plumb readings.

Adjustment for tilt & twists.

Prevent overflowing of concrete.

Maintain a free board of 100 mm.

Uniform distribution of load on the platform.

10. Lowering of unwanted materials periodically.

17. Consistent quality of concrete.

Provide coil nuts in the final layer of concrete approximately 300 mm

Remove the jacks and sleeves.

Remove the yoke assembly, which consists of yoke legs,

Remove inside & outside walers.

Remove the wall forms, while removing the waler.

Extract the jack rods and grout the holes.

10. Remove dismantling brackets after completing other works.

Provide coil nuts in the final layer of concrete.

Fix dismantling brackets, handrails, and fix the planks.

Remove and re-locate the R.G.Hoist to the required location(if it is

Remove the inside & outside hanging scaffolding.

Remove all the hydraulic hoses, manifolds and the jacks.

Remove the intermediate form supports, spindles, turnbuckle, shutters,

Remove inside & outside yoke legs.

10. Dismantle the truss assembly.

3. ACI 313-77 R83 - Recommended practice for design and construction

Erection of Access Tower (2.5 X 2.5 M)

Dismantling of Access Tower (2.5 X 2.5 M)

Erection of Stair Tower (2.5 X 2.5 M)

Dismantling of Stair Tower (2.5 X 2.5 M)

Straight Slipform Assembly

Straight Slipform Dismantling

Slipform Operation - Straight Slipform

Assembly of Pre-Stressed Silo

Slipform Concrete - Manual

Slipform Concrete - Rmc With Pump

Slipform Concrete - Rmc With Hoist

Slipform Reinforcement - Straight Slipform

Extraction of Climbing Rod

Taper Slipform Assembly - Upto 24 Yoke Set

Taper Slipform Assembly - 16 To 48 Yoke Set

Taper Slipform Dismantling - Upto 24 Yoke Set